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757

MAINTENANCE PLANNING DATA (MPD) DOCUMENT

SECTION 9

AIRWORTHINESS LIMITATIONS (AWLs) AND 

CERTIFICATION MAINTENANCE REQUIREMENTS (CM

D622N001-9

NOVEMBER 2010

COMPILED AND PUBLISHED BY:

MAINTENANCE PROGRAMS ENGINEERING

COMMERCIAL AVIATION SERVICES

BOEING COMMERCIAL AIRPLANE GROUP

SEATTLE, WASHINGTON

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TABLE OF CONTENTS

REVISIONS .......................................................................................................................................................................................LIST OF EFFECTIVE PAGES ...........................................................................................................................................................A. SCOPE..........................................................................................................................................................................................B. AIRWORTHINESS LIMITATIONS - STRUCTURAL INSPECTIONS ............................................................................................C. AIRWORTHINESS LIMITATIONS – STRUCTURAL SAFE LIFE PARTS .....................................................................................D. AIRWORTHINESS LIMITATIONS – SYSTEMS............................................................................................................................E. AIRWORTHINESS LIMITATIONS – FUEL SYSTEMS..................................................................................................................F. PAGE FORMAT: FUEL SYSTEMS AIRWORTHINESS LIMITATIONS ..........................................................................................G. AIRWORTHINESS LIMITATIONS – FUEL SYSTEM AWLS .........................................................................................................H. AIRWORTHINESS LIMITATIONS – NITROGEN GENERATION SYSTEM (NGS) ALIS AND CDCCLS .....................................I. CERTIFICATION MAINTENANCE REQUIREMENTS (CMRS)......................................................................................................J. PAGE FORMAT: CERTIFICATION MAINTENANCE REQUIREMENTS (CMRS) .........................................................................K. CERTIFICATION MAINTENANCE REQUIREMENTS TASKS......................................................................................................L. JAA UNIQUE REQUIREMENTS ...................................................................................................................................................

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REVISIONS

REVISION AND REVISION DESCRIPTION 

JUNE 1990Although this information was previously issued as Revision "B" to Section 9 of the MPD, this issue is considered the original release because it is now assigned a new document number (D622N001-9).

Prepared by:N. Ramdin (Boeing) 6/6/90

SuperviseS. J. Brad(Boeing) 

DECEMBER 1995Deleted CMR 28-41-00-5A since Airworthiness Directive 83-15-05 required installation of a new FQIS.

Prepared by:R. Moore (Boeing) 11/28/95

SuperviseS. R. Willif2/19/93

MAY 1997Revised the Airworthiness Limitations section to reflect the reassessment of the "50-series" Supplemental Structural Inspection Program.

Submitted by:S. R. Williford (Boeing) 5/21/97

Approved D. L. Rigg

NOVEMBER 1998Added Rough Runway Operation requirements. Revised Airworthiness Limitations section to show changed airplane applicability and to add 757-300 requirements. Added Engine Mount safe life limits. Deleted CMR Task Category column from Subsection E and F. Interval for CMR 26-10-00-6A changed from DAILY to 0048 HRS. Added CMRs R78-34-00-5A, R78-34-00-5B, R78-34-00-5C, R78-34-00-5D and R78-34-00-5E applicable only to the 757-300 thrust reverser system. Added CMR 26-23-01-6B for the fire protection system.Revised Airworthiness Limitations section to add JAA unique 757-300 requirements (Section G).

Submitted by:N. E. Hennigs (Boeing) 1/20/99

Approved D. L. Rigg

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MARCH 2002Revised ATA 57 Wing Airworthiness Limitations to add 3 AWLs for the Front Spar.

Prepared by:G. R. Palafox (Boeing) 3/20/02 

Approved A Pasion (

MAY 2002Revised JAA unique 757-300 requirements (Section G) to add words Rolls Royce Engine to 757-300 Mounts.Deleted "Note: The DTR Check Forms for the listed 757-300 Airworthiness Limitations will be included in the MAY 99 revision of the 757 MPD Appendix B" as this information is now included at every revision.Revised statement in preamble to Airworthiness Limitations that specifies rollback of any escalated baseline structural inspection intervals when reaching the AWL threshold.AWL airplane applicability list changed to delete PW for the Struts and add 200PW and 300PW.

Submitted by:G. R. Palafox (Boeing) 5/1/02 

Approved A Pasion (

REVISIONS

REVISION AND REVISION DESCRIPTION 

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MAY 2002 (Continued)Revised ATA 54 Strut Airworthiness Limitations to delete 2 PW AWL and 2 200RR AWL. Revised ATA 54 Strut Airworthiness Limitations to add 1 200PW AWL, 5 200RR AWL and 4 300PW AWL. Revised 3 300RR ATA 54 Strut Airworthiness Limitations to correct Zone Reference from /434 to /443.Revised Safe Life Limits to add words Rolls Royce Engine to 757-300 Mounts.Revised page format explanation for Certification Maintenance Requirements to add PW 2043 engine.Revised CMR 29-11-00-6E by adding the word "FUNCTIONALLY" to clarify the type of task. Also, revised the note in SB 29-0026 by changing the word from "DELETED" to "TERMINATED" for clarification.Revised CMR 29-11-00-6F by adding the words “FUNCTIONALLY" and "POWER' and deleting the word "GROSS” to clarify the type and level of this task.Added CMRs P78-34-00-5A, P78-34-00-5B, P78-34-00-5C, and P78-34-00-5D applicable to the 757-200/300 PW2000 Engine.CMRs are applicable to Engine 1 and 2 Thrust Reverser Sync-Lock and Auto Restow System.Added CMRs 26-23-01-6D and 26-23-01-6E applicable to the 757-300 PW2000 Engine. CMRs are applicable to the Environmental Control System (ECS) - Smoke Detection and Fire Protection System. Revised CMRs 26-23-01-6C to limit the Airplane and Engine Applicabilities as a result of the new PW Engine.

Submitted by:G. R. Palafox (Boeing) 5/1/02 

Approved A Pasion (

REVISIONS

REVISION AND REVISION DESCRIPTION 

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AUGUST 2002Added new Section D. AIRWORTHINESS LIMITATIONS - SYSTEMS and reidentified subsequent Sections E to H. This new section resulted from 757-300PW certification and contains a list of failures that are reportable.Revised 54-50-I01 MID SPAR CHORD to show correct SSI# 54-50-I01/54-50-I02. DELETED 54-50-I08 FORWARD ENGINE MOUNT and added two items 54-50-I08 FORWARD ENGINE MOUNT BEAM and 54-50-I08 FORWARD ENGINE MOUNT BOLTS to match certification data.Revised Structural Safe Life Limits for 757-300 ROLLS ROYCE ENGINE FORWARD MOUNT from 10,000 to 40,000 LANDINGS.Revised Structural Safe Life Limits for 757-300 ROLLS ROYCE ENGINE AFT MOUNT from 16,000 to 80,000 LANDINGS.Revised the following CMR numbers to agree with the corresponding tasks listed in Section 6 for consistency.P78-34-00-5A changed to P78-31-00-5CP78-34-00-5B changed to P78-31-00-5AP78-34-00-5C changed to P78-31-00-5JP78-34-00-5D changed to P78-31-00-5GRevise JAA Unique Requirements to increase Safe Life Limit of 757-300 ROLLS ROYCE ENGINE FORWARD MOUNT from 6,000 to 25,000 LANDINGS and 757-300 ROLLS ROYCE ENGINE AFT MOUNT from 10,000 to 50,000 LANDINGS.

Submitted by:G. R. Palafox (Boeing) 8/29/02

Approved L. Liu-Nels

NOVEMBER 2002Revised threshold of Airworthiness Limitations 54-50-I01/54-50-I02, 54-50-I03, 54-50-I04, 54-50-I08 and 54-50-I08 from 10,000 Cycles to 50,000 Cycles. Added CMR 52-51-00-5A to perform a functional check of the locking and unlocking latch bolt mechanism on the flight deck door decompression panel.

Submitted by:G. R. Palafox (Boeing) 11/13/02 

Approved Jeffrey Du

REVISIONS

REVISION AND REVISION DESCRIPTION 

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MAY 2003Revised Page 9.0-15 preamble to Airworthiness Limitations that specifies rollback of any escalated baseline structural inspection intervals when reaching the AWL threshold to clarify that restriction applies to flight cycles only and not calendar escalation.Revised Airworthiness Limitations Pages 9.0-29 to 9.0-35 to include flap failure mitigation requirements for 757-200 airplanes.This has resulted in revision to 26 existing limitations to change applicability from-300 to ALL and the addition of 29 limitations applicable to -200 only.Revised page 9.0-38 preamble to Certification Maintenance Requirements to make reference to Advisory Circular AC 25-19.Revised the task statements of 10 CMRs on Pages 9.1-1 through 9.1-4 to be consistent with their task codes.

Submitted by:S. A. Pierini (Boeing) 8/18/03

Approved 

JULY 2004Revised CMR 52-51-00-5A to 52-51-00-5C to correct typographical error on Page 9.1-3.

Submitted by:S. A. Pierini (Boeing) 7/21/04 

Approved 

JUNE 2005Revised CMR 31-41-02-4A Interval from 04000 Hrs to 10800 Hrs.

Submitted by:S. A. Pierini (Boeing)

Approved 

REVISIONS

REVISION AND REVISION DESCRIPTION 

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JANUARY 2006Added new fuel system airworthiness limitation which includes inspections of the center tank auto shutoff system and fuel quantity indicating system hot short protector.Added FAA AMOC Letter 120S-05-457 to reflect the approval of the June 2005 revision of Section 9.

Submitted by:S. A. Pierini (Boeing)

Approved 

FEBRUARY 2006Added Boost pump ground fault interrupt and motor operated valves AWLs.

Submitted by:S. A. Pierini (Boeing)

Approved 

MARCH 2006Added nineteen fuel system AWLs to satisfy SFAR 88 requirements.Revised 28-AWL-22 to clarify concern statement because the densitometer is not optional in the center tank.Revised 28-AWL-23 to clarify concern statement and location of bonding measurement in step 1.f.

Submitted by:G. R. Palafox (Boeing)

Approved 

OCTOBER 2006The front matter has been changed to reference the new DTR Document D622N001-DTR rather than Appendix B of the 757 MPD. D622N001-DTR was published in April 2006 and superseded Appendix B.Revised 28-AWL-23 to ensure that all motor operated valve configurations are addressed. Added new motor operated valve inspection number 28-AWL-25 applicable to airplanes that have incorporated Service Bulletin 737-28A0088

Submitted by:G. R. Palafox (Boeing)

Approved 

REVISIONS

REVISION AND REVISION DESCRIPTION 

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JANUARY 2007Revised Section E, Airworthiness Limitations - Fuel Systems, to include revisions recommended by the Seattle FAA Flight Standards Group.Revised 28-AWL-06 to add CMM Number and revision level for Honeywell FQIS system.Revised 28-AWL-07 to add CMM Number and revision level for Honeywell FQIS system fuel tank units and compensator.Revised 28-AWL-22 to clarify the bonding test requirement.Revised 28-AWL-24 to remove the ITT Actuator Part Number from the Applicability column.Added Airworthiness Limitation Number 28-AWL-26 "Center Tank Fuel Boost Pump Power Failed On Protection System" This AWL is applicable to airplanes that have incorporated Service Bulletin 757-28A0105.

Submitted by:S. A. Pierini (Boeing)

Approved 

NOVEMBER 2007Revised Section D. Airworthiness Limitations - Systems to incorporate "Reporting Uncontrollable High Thrust Failure Conditions" per FARs 121.703 and 135.415.Revised the first sentence of Section E. Airworthiness Limitations - Fuel Systems by adding “scheduled inspections and design limitations”, and revised the information on Exceptional Short-Term Extensions to clarify notification requirements.Revised the title of Section F to read “Page Format: Fuel Systems Airworthiness Limitations”.Revised the 28-AWL-21 interval from 3 years to 1 year based on updated Ground Fault Interrupter Relay supplier reliability data. 

Submitted by: E. B. Lange (Boeing) Approved 

REVISIONS

REVISION AND REVISION DESCRIPTION 

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MARCH 2008Revised 28-AWL-01 to remove 36000FH task interval limitation based upon engineering review and operator maintenance practice and removed body station and buttock line text and replaced with "per AMM 28-11-00".Revised 28-AWL-03 to reflect the new maximum loop resistance values associated with the lightning protection of the unpressurized FQIS wire bundle installations so as to satisfy the Airworthiness Limitation Instructions required by SFAR 88. Also removed the joint resistance values and 36000FH task interval limitation based upon engineering review and operator maintenance practice.Revised 28-AWL-12 to add an additional CMM references 28-22-05 Revision Number 4 and 28-22-06 Revision Number 6 to task.Revised 28-AWL-14 by removing the 36000FH task interval limitation based upon engineering review and operator maintenance practice.Revised 28-AWL-17 to change the fay surface bond limit call out for the pressure relief valve from 1 ohm or less to 0.010 ohms (10 milliohms) or less.

Submitted by: John Sabolchy (Boeing) Approved 

DECEMBER 2008Revised 28-AWL-03 to reflect the new maximum Loop Resistance Values and additional airplane configurations associated with the lightning protection of the unpressurized FQIS wire bundle installations to satisfy the Airworthiness Limitation Instructions required by SFAR 88. Revised 28-AWL-04 to provide additional clarification for Step 3.Revised 28-AWL-06 to include additional CMM reference and revision level information.Revised 28-AWL-07 to include additional CMM reference and revision level information.Revised 28-AWL-12 to include additional CMM reference and revision level information.Revised 28-AWL-16 to include updated procedures.Revised 28-AWL-17 to include updated procedures.Revised 28-AWL-23 to include updated procedures.Revised 28-AWL-24 to include additional CMM reference and revision level information.Revised 28-AWL-25 to include additional CMM reference and revision level information and updated procedures.

Submitted by: Jason Onorati (Boeing) Approved 

REVISIONS

REVISION AND REVISION DESCRIPTION 

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JULY 2010Revised Sections C and K by adding Service Letter Numbers and updating tables to reflect the Part Numbers for the Rolls Royce Engine Forward Mount.

Submitted by John Sabolchy, Boeing Approved 

NOVEMBER 2010Added new Airworthiness Limitations - Nitrogen Generation System ALIs and CDCCLs. This newly added AWL Section is now Section H with the subsequent sections being revised to I, J, K, and L, respectively.Added a new table in Section H for AWLs 47-AWL-01 through 47-AWL-06.Revised Section I by removing the CMR illustration (Figure 2) to eliminate redundancy, since the data is available for reference in the Page Format table (Section J).Revised Section J (Page Format: CMRs) by updating the MPD Item Number, Task, Zone, and Access definitions to reflect the latest publishing format and publishing locations.Revised Section K by updating the MPD Item Number and Task columns to reflect the new numbering and publishing format. Please Note: For Sections J and K, the CMR intervals/descriptions/zone/etc. for these items were not changed. For example, MPD Item Number 26-010-04 (OPC) used to be identified as MPD Item Number 26-23-01-6C (OP). Detailed Zone and Access information in Section 3 and 4 of the 757 MPD has been relocated to Appendix A of the 757 MPD.

Submitted by John Sabolchy, Boeing Approved 

REVISIONS

REVISION AND REVISION DESCRIPTION 

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A. SCOPE

The scheduled maintenance requirements described in this section result from Model 757 airplane certification activities with th

Administration (FAA). Accordingly, this FAA approved Airworthiness Limitations and Certification Maintenance Requirements dreferenced in the Model 757 Type Certificate Data Sheet. These maintenance actions are mandatory.This Airworthiness Limitations Section is FAA approved and specifies maintenance required under Federal Aviation Regulation unless an alternative program has been FAA approved.AIRWORTHINESS LIMITATIONS - STRUCTURAL INSPECTIONSThe Airworthiness Limitations may only be revised with the approval of the FAA Seattle Aircraft Certification Office (ACO).If the inspections cannot be accomplished due to repairs and/or modifications, an alternate inspection acceptable to the Seattle ROUGH RUNWAY OPERATIONThe scheduled maintenance requirements described in this section may not be valid for any 757-300 which has accumulated 5runways listed below.• All runways in the Commonwealth of Independent States (CIS), except as defined in Boeing Document D682332, Runway R

Fatigue and Damage Tolerance.

Subsection B, Airworthiness Limitations - Structural Inspections, and Subsection C, Airworthiness Limitations - Structural Safe reviewed and modified as necessary to address the increased damage which may result from operation on these rough runwayaccumulates 500 landings on the runways defined above, the operator has 3000 flight cycles (accumulated on any runway) to ichanges to this program. Contact Boeing for assistance.NOTE: Any changes to this program must be approved by the Seattle FAA ACO.Any 757-300 which uses the CIS runways defined above, must comply with the inspections specified by Service Bulletin 757-3Main Landing Gear Truck and Inner Cylinder Pivot Bushing and Bore Inspection".

NOV 1998
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CERTIFICATION MAINTENANCE REQUIREMENTS (CMRs)These scheduled maintenance tasks may only be revised by the Seattle FAA ACO. Principal Airworthiness Inspectors (local rechange these requirements or the intervals associated with these requirements.

NOV 1998
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B. AIRWORTHINESS LIMITATIONS - STRUCTURAL INSPECTIONS

INTRODUCTIONThe Structural Inspection Program approved in Section 3 of the 757 Maintenance Review Board (MRB) Report and contained i

describes an initial baseline structural maintenance program for all Structural Significant Items (SSIs). This program was devethe guidelines of MSG-3 and partially satisfies the requirements of FAR 25.571 by providing accidental and environmental damfor all SSIs, and in some cases, fatigue damage detection opportunity. The supplemental structural inspections listed in this SeLimitations, are for those SSIs that do not receive adequate fatigue damage detection opportunity from the initial baseline strucin Section 2. The inspections shown in this section are to be accomplished in conjunction with and not as a substitute for the emaintenance program found in Section 2.The supplemental structural inspection program uses the Damage Tolerance Rating (DTR) system to determine the inspectionnecessary to provide adequate fatigue damage detection. The DTR system defines a required DTR (a numerical value) that mSSI. DTR check forms which define the inspection options and the required DTR are contained in Document D622N001-DTR. THRESHOLDThe certifying authority (Seattle FAA ACO) requires designation of all SSIs into two categories. These two categories are referType 2. Type 1 structure requires the implementation threshold to be established by crack growth analysis. Type 2 structure is implementation threshold established by fatigue analysis (supported by test evidence) and allows for the future escalation of the sufficient data from the initial inspections statistically support an increased threshold.The tables shown on Pages 9.0-19 through 9.0-37 of this section (Airworthiness Limitations - Structural Limitations) defines the i

threshold. Some items are sensitive to flight length and identified by Flight Length Sensitive (FLS) in the threshold column of th

both flight hours and flight cycles to determine the implementation threshold. Refer to Figure 1, shown on the next page, to detFLS Items.

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FIGURE 1. Flight Length Sensitive (FLS) Threshold Graph

Instructions for the use of the FLS Threshold Graph:1. Determine, for each airplane, the accumulated flight cycles and flight hours.2. Enter the FLS Threshold Graph at the appropriate flight cycles and flight hours and plot the point.3. The initial supplemental inspection must be accomplished before crossing into the shaded area on the FLS Threshold Grap

10

50403020

60 80 100 120 140 160 180

CYCLES ( X 1,000)

FLIGHT HOURS ( X 1,000)

MAY 1997
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In addition to the thresholds described above, a calendar threshold of 20 years applies unless an initial inspection of an FAA apPrevention and Control Program (CPCP) has occurred, constituting CPCP implementation.When reaching the threshold of 50,000 flight cycles or the FLS cycles and hours (whichever comes first), all C-check (or higherrepeat intervals must be no greater than those shown in the MPD Section 2. Structures C-check interval is defined in Section 1 18 months. This interval restriction applies only to an extension to the flight cycle limit and not the calendar limit. This means tescalated the structures program by changing either task intervals (flight cycles) or the C-check interval (flight cycles), must redback to the MPD baseline structures program intervals before accumulating 50,000 flight cycles or the FLS cycles and hours (wreason for this is that the FAR 25.571 damage tolerance evaluation takes credit for the baseline structures program. The airwoSection 9 cover structure for which the required DTR is not satisfied by the baseline structural inspections of Section 2. Any cothe MPD baseline structures program may result in additional structure not meeting the required DTR which was the basis of ceREPEAT INSPECTION INTERVALA repeat inspection interval for the fatigue inspection of an SSI is established from its Damage Tolerance Rating (DTR) Check required DTR or the DTR curve is not allowed without approval from the Seattle FAA ACO.REPORTING RESULTS OF STRUCTURAL INSPECTIONSAll cracks found during these inspections shall be reported within ten (10) days directly to the Manager of the Seattle FAA ACODirectorate, and to Boeing Commercial Airplanes using the Discrepant Structure Report Form. Refer to Document D622N001-form (any suitable alternative which contains the same information may be used).

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The following table on Pages 9.0-19 through 9.0-40 lists the Airworthiness Limitation Structural Inspection requirements. Each SSI Number, DTR Check Form Title, Inspection Zone, Airplane Applicability, Type and Threshold. There are corresponding DTD622N001-DTR for each item listed in the table. Where there is more than one listing for a given SSI Number, the DTR Check identifier. Airplane applicability is listed as:NOTE: L/N = Airplane Line Number. Where entered with DTR Check Form Title, identifies DTR Check Form to specific airpla

ALL = All 757 AirplanesPASS = All Passenger Airplanes200 = 757-200 Airplanes200PASS = 757-200 Passenger AirplanesPF = Package FreighterCOMBI = Combi Airplanes300 = 757-300 Airplanes200RR = 200 Airplane Nacelle Strut for Rolls Royce RB211-535300RR = 300 Airplane Nacelle Strut for Rolls Royce RB211-535200PW = 200 Airplane Nacelle Strut for Pratt & Whitney PW2000300PW = 300 Airplane Nacelle Strut for Pratt & Whitney PW2000

OCT 2006
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AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS

SSI # DTR CHECK FORM TITLE

ZONE

REF

AIRPLANE 

APPLICABILIT

52-10-06 Fuselage Main Deck Cargo Door Skin and Frames BS480 to BS620 Upper Hinge Line to S-14 838 PF

COMBI

52-10-06 Fuselage Main Deck Cargo Door Frames BS487.1 BS500 BS520 BS540 BS560 BS580 BS600 

BS612.9 below S-14

838 PF

COMBI

52-30-02 Fuselage Lower Lobe Cargo Compartment Door No. 1 & No. 2, Stop Beams Outer Chord 821/822 ALL 52-30-04 Fuselage Lower Lobe Cargo Compartment Door No. 3, Stop Beams Outer Chord (if No. 3 Cargo 

Door Installed)

823 200PASS 

53-10-14 No. 1 Window Cutout Structure AB Post 211/212 ALL 

53-10-14 No. 1 Window Cutout Structure BD Sill, L & R 211/212 ALL 

53-10-15 No. 2 Window Cutout Structure EF Post, L & R 211/212 ALL 

53-10-18 BS 263 Bulkhead, Inner Chord BL27 to BL50 L & R 113/114 ALL 

53-10-18 BS 263 Bulkhead, Outer Chord S-23L to S-23R 113/114 ALL 

53-10-18 BS 263 Bulkhead, Outer Chord BL27L to BL27R 115/116 ALL 53-10-18 BS 263 Bulkhead, Outer Chord BL27L to BL27R (Flange Not Covered) 115/116 ALL 

53-10-18 BS 263 Bulkhead, Outer Chord BL27L to BL27R (Flange Covered) 115/116 ALL 

53-10-18 BS 263 Bulkhead, Outer Chord Sensor Locations LBL 6.5, L & R 115/116 ALL 53-10-18 BS 263 Bulkhead, Outer Chord Intercostal Locations BL27L to BL27R 113/114 ALL 

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53-10-21 BS 395 Bulkhead, Outer Chord S-20 to S-26 L & R 115/116,

119

ALL 

53-10-21 BS 395 Bulkhead, Outer Chord S-26L to S-26R 115/116,

119

ALL 

53-10-21 BS 395 Bulkhead, Outer Chord S-28 L & R 115/116,

119

ALL 

53-10-21 BS 395 Bulkhead, Outer Chord S-27 L & R 115/116,

119

ALL 

53-10-3053-30-2453-40-3253-60-24

Typical Upper Frame BS 365.25 to BS 1720, S-13L to S-13R 200 ALL 

53-10-3053-30-2453-40-3253-60-24

Typical Lower Frame BS 365.25 to BS 1720, S-13L to S-13R 100/200 ALL 

53-30-0753-60-07

Fuselage Skin Lap Splices, Upper Fastener Row, L & R 100/200 200PASS

COMBI

53-30-0753-60-07

Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row, S-4, S-10, S-19, S-20, L & R 100/200 200PASS

COMBI

53-30-0753-60-07

Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row, S-14, L & R 100/200 200PASS

COMBI

53-30-0753-60-07

Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row, S-26, L & R 100/200 200PASS

COMBI

53-30-0753-60-07

Fuselage Skin Lap Splices, Upper Fastener Row, L & R 100/200 PF 

53-30-0753-60-07

Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row S-4, S-10, S-14, S-19, S-20, L & R

100/200 PF 

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APPLICABILIT

MAY 2003
757 MAINTENANCE PLANNING DATA

D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-30-0753-60-07

Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row S-26, L & R 100/200 PF 

53-30-0753-60-07

Fuselage Skin Lap Splices, Upper Fastener Row, L & R 100/200 300 

53-30-0753-60-07

Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row S-4, S-10, S-14, S-19, S-20, L & R

100/200 300 

53-30-0753-60-07

Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row S-26, L & R 100/200 300 

53-30-11 No. 1 Cargo Door Cutout BS 560 Edge Frame Inner Chord Upper Sill to S-24, L/N 1 - 57 122 200PASS 53-30-11 No. 1 Cargo Door Cutout BS 560 Edge Frame Inner Chord Upper Sill to S-24, L/N 58 and on 122 ALL 53-30-11 No. 1 Cargo Door Cutout BS 560 Edge Frame Outer Chord Upper Sill to Lower Sill, L/N 1 - 57 122 200PASS 53-30-11 No. 1 Cargo Door Cutout BS 560 Edge Frame Outer Chord Upper Sill to Lower Sill, 

L/N 58 and on

122 ALL 

53-30-11 No. 1 Cargo Door Cutout BS 620 Edge Frame Inner Chord S-20 to Lower Sill, L/N 1 - 57 122 200PASS 53-30-11 No. 1 Cargo Door Cutout BS 620 Edge Frame Inner Chord S-20 to Lower Sill, L/N 58 and on 122 ALL 53-30-11 No. 1 Cargo Door Cutout BS 620 Edge Frame Outer Chord Upper Sill to Lower Sill, L/N 1 -57 122 200PASS 53-30-11 No. 1 Cargo Door Cutout BS 620 Edge Frame Outer Chord Upper Sill to Lower Sill, L/N 58 

and on

122 ALL 

53-30-12 No. 1 Cargo Door Cutout Door Stop Intercostals at Stops 1 & 6 122 ALL 53-10-1053-30-13

No. 1 & 2 Passenger Door Cutouts Forward Frame Inner Chord 221, 231/

222, 232

PASS

COMBI

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MAY 2003
D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

757 MAINTENANCE PLANNING DATA

53-10-1053-30-13

No. 1 & 2 Passenger Door Cutouts Forward Frame Outer Chord 221, 231/

222, 232

PASS

COMBI

53-10-1053-30-13

1 & 2 Passenger Door Cutouts Upper Main Sill Outer Chord 221, 231/

222, 232

PASS

COMBI

53-10-1053-30-13

No. 1 & 2 Passenger Door Cutouts Upper Main Sill Inner Chord 221, 231/

222, 232

PASS

COMBI

53-30-22 Main Deck Cargo Door Cutout Frames BS480 and BS620 Inner Chord Upper to Lower Sill 231 PF

COMBI

53-30-22 Main Deck Cargo Door Cutout Frames BS480 and BS620 Outer Chord Upper to Lower Sill 231 PF

COMBI

53-30-22 Main Deck Cargo Door Cutout Upper Sill Inner Chord BS470 to BS495 and BS605 to BS630 231 PF

COMBI

53-30-22 Main Deck Cargo Door Cutout Upper Sill Outer Chord BS470 to BS487 and BS613 to BS630 231 PF

COMBI

53-30-22 Main Deck Cargo Door Cutout Lower Sill Outer Chord BS470 to BS510 and BS600 to BS630 231 PF

COMBI

53-30-2453-60-24

Typical Upper Frame BS680 to BS800 and BS1400 to BS1620 200 PF

COMBI

53-30-2453-60-24

Typical Lower Frame BS460 to BS540, BS560 to BS620, BS1320 to BS1440 and BS1540 to BS1701

100 PF

COMBI

53-40-05 Circumferential Skin Splice, BS900, S-6L to S-6R 233, 234/

243, 244

200 

53-40-05 Circumferential Skin Splice, BS1180, S-6L to S-6R 243, 244/

253, 254

200 

53-40-17 Transverse Floor Beam Upper Chord, BS1100 & BS1140, BL 36 to Frame Splice, L & R 141/142 ALL 53-40-17 Transverse Floor Beam Upper Chord, BS1100 & BS1140, LBL 45.5 & RBL 45.5 141/142 ALL 

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BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-40-17 Transverse Floor Beam Lower Chord, BS1120 & BS1140, BL 17 to BL 45.5 at Horizontal 

Stiffener Locations, L & R

141/142 ALL 

53-40-17 Transverse Floor Beam Lower Chord, BS1120 & BS1140, BL 17 to BL 45.5 between Horizontal 

Stiffener Locations, L & R

141/142 ALL 

53-40-17 Transverse Floor Beam Lower Chord, BS1140 at BL 37, L & R 141/142 ALL 53-40-20 Rear Spar Bulkhead Inner Chord BS1040 S-14 to S-17 L & R 241/242 ALL 53-40-20 Rear Spar Bulkhead Lower Side Fitting Inboard Leg BS1040 L & R 241/242 ALL 53-40-21 BS 1180 Aft Wheel Well Bulkhead Inner Chord at S-12L & S-12R 241/242 ALL 53-40-21 BS 1180 Aft Wheel Well Bulkhead Inner Chord from S-11 to S-15, L & R 241/242 ALL 53-40-21 BS 1180 Aft Wheel Well Bulkhead Lower Chord from S-21 to S-26, L & R 151/152 ALL 53-40-21 BS 1180 Aft Wheel Well Bulkhead Vertical Beam, L & R 151/152 ALL 53-40-2253-40-24

MLG Beam Support Frame Inner Chord BS1080 & BS1140 S-14 to S-16 L & R 241/242 ALL 

53-40-23 MLG Beam Support Frame Inner Chord BS1120 S-14 to S-16 L & R 241/242 ALL 53-40-2353-40-24

MLG Beam Support Frame at Floor Beam Splice BS1120 and BS1140 L & R 241/242 ALL 

53-40-25 Overwing Stub Frames Inner Chord BS1000 and BS1020 L and R (Not Applicable to Overwing 

Exit Models)

241/242 200PASS 

53-40-28 Overwing Exit Cutout Upper Sill Inner Chord BS950 to BS976 and BS990 to BS1012 L & R 241/242 PASS

COMBI

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MAY 2003
D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

757 MAINTENANCE PLANNING DATA

53-40-28 Overwing Exit Cutout Upper Sill Outer Chord BS960 to BS1020 241/242 PASS

COMBI

53-40-28 Overwing Exit Cutout Lower Sill Outer Chord BS1004 to BS1030 L & R 241/242 200PASS 

COMBI

53-40-28 Overwing Exit Cutout Lower Sill Outer Chord BS1004 to BS1030 L & R 241/242 300 53-60-09 Circumferential Splice Plate BS1460 S-6L to S-6R 253/254 ALL 

53-60-09 Circumferential Splice Plate BS1620 S-6L to S-6R 253/254 ALL 

53-60-11 No. 2 Cargo Door Cutout BS1380 Edge Frame Inner Chord S-23 to Lower Sill, L/N 1 - 57 154 200PASS 53-60-11 No. 2 Cargo Door Cutout BS1380 Edge Frame Inner Chord S-23 to Lower Sill, L/N 58 and on 154 ALL 

53-60-11 No. 2 Cargo Door Cutout BS1380 Edge Frame Outer Chord S-21 to Lower Sill, L/N 1 - 57 154 200PASS 

53-60-11 No. 2 Cargo Door Cutout BS1380 Edge Frame Outer Chord S-21 to Lower Sill, L/N 58 and on 154 ALL 53-60-11 No. 2 Cargo Door Cutout BS1440 Edge Frame Inner Chord S-20 to Lower Sill, L/N 1 - 57 154 200PASS 53-60-11 No. 2 Cargo Door Cutout BS1440 Edge Frame Inner Chord S-20 to Lower Sill, L/N 58 and on 154 ALL 

53-60-11 No. 2 Cargo Door Cutout BS1440 Edge Frame Outer Chord Upper Sill to Lower Sill, L/N 1 - 57 154 200PASS 53-60-11 No. 2 Cargo Door Cutout BS1440 Edge Frame Outer Chord Upper Sill to Lower Sill, L/N 58 

and on

154 ALL 

53-60-12 No. 2 Cargo Door Cutout Corner Door Stop Intercostals, Web at Stops 1 and 6 154 ALL 

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MAY 2003
757 MAINTENANCE PLANNING DATA

D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-60-12 No. 2 Cargo Door Cutout Door Stop Intercostal, Web at Stop 4 154 ALL 

53-60-13 No. 3 Emergency Exit Cutout Forward Frame Inner Chord BS1320 S-12 to S-16 L & R 

(Not Applicable to 757-200 Overwing Exit Models)

251/152 PASS 

53-60-13 No. 3 Emergency Exit Cutout Forward Frame Inner Chord BS1320, S-17 at Sill L & R 

(Not Applicable to 757-200 Overwing Exit Models)

251/252 PASS 

53-60-13 No. 3 Emergency Exit Cutout Aft Frame Outer Chord BS1350 S-10 to S-12 L & R 

(Not Applicable to 757-200 Overwing Exit Models)

251/252 PASS 

53-60-13 No. 3 Emergency Exit Cutout Aft Frame Inner Chord BS1350 S-10 to S-12 L & R 

(Not Applicable to 757-200 Overwing Exit Models)

251/252 PASS 

53-60-13 No. 3 Emergency Exit Cutout Upper Main Sill Outer Chord between BS1300 to BS1320 and 

BS1350 to BS1380 L & R (Not Applicable to 757-200 Overwing Exit Models)

251/252 PASS 

53-60-13 No. 3 Emergency Exit Cutout Upper Main Sill Inner Chord BS1350 to BS1380 L & R 

(Not Applicable to 757-200 Overwing Exit Models)

251/252 PASS 

53-60-13 No. 3 Emergency Exit Cutout - Fwd and Aft Frames - Outer Chord BS1320 & BS1350 - Upper Sill 

Intersection (Not Applicable to 757-200 Overwing Exit Models)

251/252 PASS 

53-60-15 No. 4 Passenger Door Cutout Forward Frame Outer Chord BS1640 S-9 to S-17 L & R 251/252 PASS

COMBI

53-60-15 No. 4 Passenger Door Cutout Forward Frame Inner Chord BS1640 S-14 to S-17 L & R 251/252 PASS

COMBI

53-60-15 No. 4 Passenger Door Cutout Upper Main Sill Outer Chord BS1681.8 to BS1720 L & R 251/252 PASS

COMBI

53-60-15 No. 4 Passenger Door Cutout Upper Main Sill Inner Chord BS1681.1 to BS1720 L & R 251/252 PASS

COMBI

53-60-21 No. 3 Cargo Door Cutout BS1540 Edge Frame, Inner Chord S-23 to Lower Sill, L/N 1 - 57 

(if No. 3 Door Installed)

162 200PASS 

53-60-21 No. 3 Cargo Door Cutout BS1540 Edge Frame, Inner Chord S-23 to Lower Sill, L/N 58 - and on 

(if No. 3 Door Installed)

162 200PASS 

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APPLICABILIT

MAY 2003
D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

757 MAINTENANCE PLANNING DATA

53-60-21 No. 3 Cargo Door Cutout BS1540 Edge Frame, Outer Chord S-21 to S-26, L/N 1 - 57 

(if No. 3 Door Installed)

162 200PASS 

53-60-21 No. 3 Cargo Door Cutout BS1540 Edge Frame, Outer Chord S-21 to S-26, L/N 58 and on

(if No. 3 Door Installed)

162 200PASS 

53-60-21 No. 3 Cargo Door Cutout BS1592 Edge Frame, Inner Chord Upper Sill to S-25, L/N 1 - 57 

(if No. 3 Door Installed)

162 200PASS 

53-60-21 No. 3 Cargo Door Cutout BS1592 Edge Frame, Inner Chord Upper Sill to S-25, L/N 58 and on 

(if No. 3 Door Installed)

162 200PASS 

53-60-21 No. 3 Cargo Door Cutout BS1592 Edge Frame, Outer Chord S-20 to S-25, L/N 1 - 57 

(if No. 3 Door Installed)

162 200PASS 

53-60-21 No. 3 Cargo Door Cutout BS1592 Edge Frame, Outer Chord S-20 to S-2, L/N 58 and on 

(if No. 3 Door Installed)

162 200PASS 

53-60-22 No. 3 Cargo Door Cutout Door Stop Intercostals, Web (if No. 3 Door Installed) 162 200PASS 

53-80-03 BS1720 Pressure Bulkhead, Vertical Stiffener, RBL & LBL 9.2, at Back to Back Stiffeners from 

WL 219.5 to WL 246.2

311/312 ALL 

53-80-03 BS1720 Pressure Bulkhead, Vertical Stiffener, RBL & LBL 9.2, between Stiffeners from 

WL 219.5 to WL 246.2

311/312 ALL 

53-80-03 BS1720 Pressure Bulkhead, Vertical Stiffener, RBL & LBL 26.7, at Back to Back Stiffeners from 

WL 219.5 to WL 246.2

311/312 ALL 

53-80-03 BS1720 Pressure Bulkhead, Vertical Stiffener, RBL & LBL 26.7, between Back to Back Stiffeners 

from WL 219.5 to WL 246.2

311/312 ALL 

53-80-03 BS1720 Pressure Bulkhead, Vertical Stiffener, RBL & LBL 45.7, at Back to Back Stiffeners from 

WL 219.5 to WL 255.8

311/312 ALL 

53-80-03 BS1720 Pressure Bulkhead, Vertical Stiffener, RBL & LBL 45.7, between Back to Back Stiffeners 

from WL 219.5 to WL 255.8

311/312 ALL 

53-80-03 BS1720 Pressure Bulkhead, Transverse Beam, WL 265, RBL & LBL 26.7 at BL 26.7 

Stiffener Fitting

311/312 200 

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APPLICABILIT

MAY 2003
757 MAINTENANCE PLANNING DATA

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BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-80-03 BS1720 Pressure Bulkhead, Transverse Beam, WL 265, RBL & LBL 26.7 at BL 26.7 

Stiffener Fitting

311/312 300 

53-80-03 BS1720 Pressure Bulkhead, Transverse Beam, WL 265, between Vertical Stiffeners at BL 9.2 & 

BL 26.7, Left and Right

311/312 200 

53-80-03 BS1720 Pressure Bulkhead, Transverse Beam, WL 265, between Vertical Stiffeners at BL 9.2 & 

BL 26.7, Left and Right

311/312 300 

53-80-20 Horizontal Stabilizer Jackscrew Support Fitting Support Lug, BS1771.1 311/312 ALL 53-80-21 Horizontal Stabilizer Hinge Fitting Pivot Lugs, BS1858.9 313/314 ALL 

54-50-I02 Basic Chord Structure 

54-50-I03 Forward Engine Mount Bulkhead 433/443 200PW 

54-50-I03 Forward Engine Mount Fitting Pad NSta 106 and NSta 116 433/443 200PW 

54-50-I03 Forward Engine Mount Fitting Assembly 54-50-I03 Basic Chord Structure 

54-50-I04 Aft Engine Mount Bulkhead - Barrel Nut Bore 434/444 200PW 

54-50-I07 Midchord Structure 

54-50-01 Basic Upper Spar Center Chord Structure NSta 150 to 170 432/442 200RR 

54-50-03 Lower Spar Chord NSta 150 to 160 433/443 200RR 54-50-03 Aft Mount Barrel Nut Bores NSta 185.35 434/444 200RR 

54-50-04 Forward Engine Mount Bulkhead Flange NSta 100 434/444 200RR 

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APPLICABILIT

MAY 2003
D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

757 MAINTENANCE PLANNING DATA

54-50-04 Forward Engine Mount Bulkhead Barrel Nut Bores NSta 100 434/444 200RR 

54-50-I0154-50-I02

Mid Spar Chord 433/443 300PW 

54-50-I03 Forward Engine Mount Fitting 433/443 300PW 

54-50-I04 Aft Engine Mount Bulkhead 434/444 300PW 

54-50-I08 Forward Engine Mount Beam 433/443 300PW 54-50-I08 Forward Engine Mount Bolts 433/443 300PW 

54-50-03 Lower Spar Chord NSta 110.00 to 125.00 433/443 300RR 

54-50-03 Lower Spar Chord NSta 119.30, Lower Flange 433/443 300RR 54-50-03 Lower Spar Chord NSta 170.00 Beneath Precooler Fitting 433/443 300RR 54-50-03 Aft Mount Barrel Nut Bores NSta 185.35, NWL 134.85 434/444 300RR 54-50-04 Fwd Mount Barrel Nut Bores NSta 103.01, NWL 143.29 433/443 300RR 

55-10-03 Horizontal Stabilizer Rear Spar Upper Chord Horizontal Flanges (Chord at Rib 3 BBL 34.90) 331/341 ALL 

55-10-03 Horizontal Stabilizer Rear Spar Upper Chord Vertical Leg (Chord at Rib 3 BBL 34.90) 331/341 ALL 

55-10-08 Horizontal Stabilizer Upper Surface Stiffened Panel Inboard of Rib 3 (Stringer Number 1 at 

Centerline Splice BBL 0.0)

331/341 ALL 

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APPLICABILIT

MAY 2003
757 MAINTENANCE PLANNING DATA

D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

55-10-08 Horizontal Stabilizer Upper Surface Stiffened Panel Inboard of Rib 3 (Stringer Number 1 at Rib 3) 331/341 ALL 

55-10-10 Horizontal Stabilizer Rear Spar Upper Chord at Center Line Splice (Chord and Skin at BBL 0.0) 331/341 ALL 

55-10-17 Horizontal Stabilizer Rear Spar Splice Fitting, Centerline Splice (BBL 0.0) 331/341 ALL 

55-10-19 Horizontal Stabilizer Hinge Pivot Support Fitting (Side of Body at Rear Spar - Fwd of Bore) 331/341 ALL 

55-10-19 Horizontal Stabilizer Hinge Pivot Support Fitting (Side of Body at Rear Spar - Aft of Bore) 331/341 ALL 

55-10-20 Horizontal Stabilizer Jackscrew Fitting Lugs and Attachments (Lugs at BBL 0.0) 331/341 ALL 55-10-22 Horizontal Stabilizer Rear Spar Web at Rib 3 (Web at Pivot Attachment BBL 34.9) 331/341 ALL 

55-10-24 Horizontal Stabilizer Rear Spar Stiffened Web Inboard of Rib 3, (Web at Centerline Splice 

BBL 0.0)

331/341 ALL 

55-10-27 Horizontal Stabilizer Pivot Fitting Chordwise Attachment Splice Rib 3 (Upper and Lower Surface 

of Splice Plates BBL 34.9)

331/341 ALL 

57-10-07 Lower Rear Spar Chord, WBL 7.5 133/134 ALL 

57-10-07 Lower Rear Spar Chord, WBL 10.0 to 53.0 133/134 ALL 

57-10-10 Side of Body, Lower Chord, Center Wing, WBL 70.75, Rear Spar to Stringer 8 Centerline

(1) All Except L/N 804, 810, 818, 839, 846, 849 and 855.(2) L/N 804, 810, 818, 839, 846, 849 and 855. 

133/134 ALL

 See (1) and (2)

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D622N001-9

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757 MAINTENANCE PLANNING DATA

57-10-17 Lower Rear Spar Chord, Side of Body Splice, Center Wing, WBL 70.75 133/134 200 57-10-17 Lower Rear Spar Chord, Side of Body Splice, Center Wing, WBL 70.75 133/134 300 

57-20-07 Typical Stringer at Shear Tie, Skin Under Fitting Stringer 11 at WS 313.5 541/641 ALL 57-20-10 Lower Splice Stringer 5 and Stringer 10 WS 231.5 541/641 ALL 

57-20-11 Lower Rear Spar Chord WS 177.5 551/651 200 

57-20-11 Lower Rear Spar Chord WS 177.5 531, 551/ 

631, 651

300 

57-20-11 Lower Spar Rear Chord WS 204.5, Horizontal Flange 531/631 ALL 57-20-11 Lower Rear Spar Chord WS 204.5, Vertical Flange 551/651 200 

57-20-11 Lower Rear Spar Chord WS 204.5, Vertical Flange 551/651 300 

57-20-11 Lower Rear Spar Chord WS 210.3 & WS 222.2, MLG Trunnion Support 531/631 ALL 57-20-11 Lower Rear Spar Chord WS 231.5 551/651 200 

57-20-11 Lower Rear Spar Chord WS 231.5 551/651 300 

57-20-11 Lower Rear Spar Chord WS 285 551/651 ALL 

57-20-11 Lower Rear Spar Chord WS 302 541/641 ALL 

AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS

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APPLICABILIT

MAY 2003
757 MAINTENANCE PLANNING DATA

D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

57-20-11 Lower Rear Spar Chord WS 313.5 541/641 ALL 

57-20-11 Lower Rear Spar Chord WBL 70.75 to WS 204.5, General Section 531/631 300 57-20-11 Front Spar Lower Chord WS 258.5 Under Rib Post, L/N 1010 and on 511/611 200 

57-20-11 Front Spar Lower Chord WS 285.65 at Rib Fitting and Nacelle Support Fitting, L/N 1010 and on 511/611 200 

57-20-11 Front Spar Lower Chord Outboard Wing - WSta 294 511/611 ALL 

57-20-15 Typical Stringer In Dry Bay Region Stringer at Seal Pans, Skin Under Fitting, Stringer 13 at 

WS 285.65

532/632 ALL 

57-20-15 Typical Stringer In Dry Bay Region Stringer Hidden, Skin Under Fairing, Stringer 13 at WS 313.5 532/632 ALL 57-20-17 Side of Body Lower Chord, Outboard Wing, WBL 70.75, Rear Spar to Stringer 8

(1) All Except L/N 804, 810, 818, 839, 846, 849 and 855.(2) L/N 804, 810, 818, 839, 846, 849 and 855.

531/631 ALL

See (1) and (2)

57-20-25 Lower Rear Spar Chord, Side of Body Splice, Outboard Wing, WBL 70.75 551/651 200 57-20-25 Lower Rear Spar Chord, Side of Body Splice, Outboard Wing, WBL 70.75 551/651 300 57-53-01 Outboard Flap, Outboard Track Assembly (Track # 1) Forward Clevis 574/674 ALL 57-53-0157-53-03

Outboard Flap, Inbd & Outbd Track Assys (Tracks # 1 & # 2) Forward Section 573, 574/ 

673, 674

ALL 

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APPLICABILIT

MAY 2003
D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

757 MAINTENANCE PLANNING DATA

57-53-0257-53-04

Outboard Flap, Inbd & Outbd Flap Tracks (Tracks # 1 & # 2) Support Fitting Assembly 573, 574/ 

673, 674

ALL 

57-53-03 Outboard Flap, Inboard Track Assembly (Track # 2) Forward Clevis 573/673 ALL 

57-53-05 Inboard Flap, Outbd Track Assy (Track # 3) Track at Fwd Attach Lug 572/672 ALL 57-53-05 Inboard Flap, Outboard Track Assy (Track # 3) Forward Clevis 572/672 200 57-53-05 Inboard Flap, Outboard Track Assy (Track # 3) Forward Clevis 572/672 300 57-53-05 Inboard Flap, Outboard Track (Track # 3) Midsection 572/672 200 57-53-06 Inboard Flap, Outboard Track (Track # 3) Forward Support Fitting 572/672 200 57-53-06 Inboard Flap, Outboard Track (Track # 3) Forward Support Fitting 572/672 300 57-53-06 Inboard Flap, Fwd Support, Outboard Track (Track # 3) Fuse Pin 572/672 ALL 57-53-07 Inboard Flap, Inboard Support Aft Link Assy, Lower Lug 143/144 ALL 

57-53-07 Inboard Main Flap, Inboard Carriage #4, Aft Link Assy 143/144 200 57-53-07 Inboard Flap, Inboard Support Aft Link Assy, Upper Clevis 143/144 300 

AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS

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MAY 2003
757 MAINTENANCE PLANNING DATA

D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

57-53-08 Inboard Flap, Aft Link Assy Upper and Lower Special Bolts 143/144 ALL 

57-53-09 Inboard Flap, Inboard Track (Track # 4) Forward Lug 143/144 ALL 

57-53-09 Inboard Flap, Inboard Track (Track # 4) Aft Lug 143/144 ALL 

57-53-09 Inboard Flap, Inboard Track (Track # 4) Aft Curved "T" Section 143/144 200 

57-53-09 Inboard Flap, Inboard Track (Track # 4) Aft Curved "T" Section 143/144 300 

57-53-10 Inboard Flap, Inboard Track (Track # 4) Forward Support Fitting 143/144 ALL 

57-53-10 Inboard Flap, Forward Support Fitting Special Bolt 143/144 ALL 

57-53-11 Inboard Flap, Inboard Support Beam Inboard Lug 143/144 ALL 57-53-11 Inboard Flap, Inboard Support Beam Assy Outboard Lug 143/144 ALL 

57-53-12 Inboard Flap, Front Spar Upper, MF Sta 90-190 555/655 200 

57-53-12 Inboard Flap, Front Spar at Upper Skin Attachment MF Sta 80-190 555/655 300 

57-53-12 Inboard Flap, Front Spar at Upper Skin Attachment MF Sta 147-153.4 555/655 200 57-53-12 Inboard Flap, Front Spar Lower, MF Sta 210-247 555/655 200 

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MAY 2003
D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

757 MAINTENANCE PLANNING DATA

57-53-12 Inboard Flap, Front Spar at Lower Skin Attachment MF Sta 210-235 555/655 300 

57-53-13 Inboard Flap, Rear Spar Upper, MF Sta 91-190 555/655 200 57-53-13 Inboard Flap, Rear Spar at Upper Skin Attachment MF Sta 80-190 555/655 300 

57-53-13 Inboard Flap, Rear Spar Upper, MF Sta 147-153.4 555/655 200 57-53-13 Inboard Flap, Rear Spar Lower, MF Sta 210-247 555/655 200 57-53-13 Inboard Flap, Rear Spar at Lower Skin Attachment MF Sta 210-235 555/655 300 

57-53-13 Inboard Flap, Rear Spar Lower, MF Sta 215.67, 227.28, 235.1 555/655 200 57-53-13 Inboard Flap - Rear Spar Cutouts 555/655 200 57-53-13 Inboard Main Flap - Rear Spar Cutouts MF Sta 88, 150.3, 212.5 555/655 300 

57-53-14 Inboard Flap, Upper Skin MF Sta 147, 153.5 555/655 200 

57-53-15 Inboard Main Flap, Lower Skin MF Sta 235, 227 555/655 200 57-53-16 Inboard Flap, Carriage Rib 555/655 200 57-53-20 Inboard Flap - Torque Tube 143/144 ALL 

57-53-22 Inboard Flap, Outbd Carriage (Carriage # 3) Fwd Airload Roller Lug 572/672 200 

AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS

SSI # DTR CHECK FORM TITLE

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57-53-22 Inboard Flap, Outbd Carriage (Carriage # 3) Fwd Airload Roller Lug 572/672 300 

57-53-22 Inboard Flap, Outbd Carriage (Carriage # 3) Aft Airload Roller Lug 572/672 ALL 

57-53-22 Inboard Flap, Outboard Carriage Support (Carriage # 3) Aft Roller Support - Flange 572/672 ALL 

57-53-23 Inboard Flap, Inboard Carriage (Carriage # 4) Aft Roller Support - Upper Attachment Bolt 143/144 ALL 

57-53-23 Inboard Flap, Inboard Carriage (Carriage # 4) Upper Fitting Flange (Bolt Attachments) 143/144 ALL 

57-53-23 Inboard Flap, Inboard Carriage (Carriage # 4) Aft Roller Support 143/144 ALL 

57-53-23 Inboard Main Flap, Inboard Carriage, Carriage Flange 143/144 200 

57-53-23 Inboard Flap, Inboard Carriage (Carriage # 4) Carriage Flanges 143/144 300 57-53-24 Outboard Flap, Inboard and Outboard Carriages (# 1 & # 2) Airload Roller Bosses (Lugs) 573, 574/ 

673, 674

ALL 

57-53-25 Outboard Flap, Inboard and Outboard Carriages (# 1 & # 2) Aft Bridge Fitting Lugs 573, 574/ 

673, 674

ALL 

57-53-26 Outboard Flap, Front Spar Upper, WBL 405-471 566/666 200 57-53-26 Outboard Flap, Front Spar at Upper Skin Attachment MF Sta 405-471 566/666 300 57-53-26 Outboard Main Flap, Front Spar Lower Chord, WBL 349-405 & 471-506 566/666 200 

AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS

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REF

AIRPLANE 

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757 MAINTENANCE PLANNING DATA

57-53-26 Outboard Flap, Front Spar at Lower Skin Attachment MF Sta 300-405 566/666 300 57-53-27 Outboard Main Flap, Rear Spar WBL 405-471 Upper Chord 566/666 200 57-53-27 Outboard Main Flap, Rear Spar Lower WBL 349-405 & 471-506 566/666 200 57-53-27 Outboard Flap, Rear Spar at Lower Skin Attachment MF Sta 300-405 566/666 300 

57-53-27 Outboard Flap, Rear Spar at Lower Skin Attachment MF Sta 494-554 566/666 300 

57-53-27 Outboard Flap Rear Spar, Rear Spar Cutouts 566/666 200 

57-53-27 Outboard Main Flap, Rear Spar Cutouts 566/666 300 

57-53-28 Outboard Flap, Upper Skin Splice, Upper Skin, WBL 405.4 566/666 200 

57-53-28 Outboard Flap, Torque Box Upper Skin Splice at WBL 405 566/666 300 

57-53-29 Outboard Flap, Lower Skin WBL 361 & 494 566/666 200 

57-53-30 Outboard Flap, Carriage Support Rib 566/666 200 57-53-31 Outboard Main Flap, Front Spar Support Fittings 566/666 200 57-53-31 Outboard Flap Front Spar Support Fittings 573, 574/ 

673, 674

300 

57-53-32 Outboard Flap Rear Spar Support Fittings 573, 574/ 

673, 674

ALL 

AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS

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REF

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57-53-33 Outboard Flap, Carriage # 1 Aft Link Lugs, WBL 493.0 574/674 200 

57-53-33 Outboard Flap, Outboard Carriage (Carriage # 1) Aft Link 574/674 ALL 

57-53-34 Outboard Flap, Inboard Carriage (Carriage # 2) Aft Link 573/673 ALL 

57-53-34 Outboard Flap, Inboard Carriage # 2 Aft Link Lugs, WBL 361.0 573/673 200 

57-53-34 Outboard Flap, Inbd and Outbd Carriages (# 1 & # 2) Aft Link - Lugs 573, 574/ 

673, 674

300 

57-53-34 Outboard Flap, Inbd and Outbd Carriages (# 1 & # 2) Aft Link Attach Bolts 573, 574/ 

673, 674

ALL 

AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS

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757 MAINTENANCE PLANNING DATA

C. AIRWORTHINESS LIMITATIONS – STRUCTURAL SAFE LIFE PARTS

NOTE: Boeing Drawing 161N0006, 757 Main Landing Gear Component Interchangeability List, and 162N0006, 757 Nose Lan

Interchangeability List, identify the 757 landing gear and support structure safe-life (life limited) parts. These drawings Service Letter 757-SL-32-030.

NOTE: Boeing Document D101N801-45, 757 Rolls Royce Engine Mount Safe Life Part Numbers, identifies all 757-300 Rolls 

(life limited) parts. This document is distributed by Service Letter 757-SL-71-019.

ITEM LIFE LIMIT

757 Nose Landing Gear 103,000 Landings (1)757 Main Landing Gear 103,000 Landings (1)757 Main Landing Gear Support Structure 103,000 Landings (1)

(1) These values are based on fatigue tests and analysis. They also assume the incorporation of the following Service Bulletins on

 applicable airplanes:

SERVICE BULLETIN #

EFFECTIVITY

LINE NUMBER DESCRIPTION

LIFE LIMIT (LAN

PRIOR TO INCOR

757-32-0013 1-30, 32-34, 36 MLG Downlock Spindle Part # 161N3006 3,500

757-57-0004 1-33 MLG Forward Trunnion Support Bearing Housing Part # 113N1062 13,700757-57-0016 1-89 & 90-133, 136 MLG Rear Trunnion Support Part # 113N1011 22,000

757-57-0015 1-82 MLG Actuator Yoke Fitting Part # 113N1032 36,000

ITEM LIFE LIMIT

757-300 Rolls Royce Engine Forward Mount except P/N FW62968 80,000 Landings757-300 Rolls Royce Engine Forward Mount P/N FW62968 36,000 Landings (2)757-300 Rolls Royce Engine Aft Mount 80,000 Landings(2) Rolls Royce Service Bulletin RB.211-71-AG051 replaces thrust bearing housing P/N LK83059 with P/N FW62968, which will be 

 in the Group B Parts Mandatory Inspections section of the RB.211-535 Time Limits Manual, 05-20-02.

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D. AIRWORTHINESS LIMITATIONS – SYSTEMS

REPORTING UNCONTROLLABLE HIGH THRUST FAILURE CONDITIONS

Title 14 Code of Federal Regulations Sections 121.703 and 135.415 state that “each certificate holder shall report any failure, maircraft, system, component, or powerplant that occurs or is detected at any time if, in its opinion, that failure, malfunction, or demay endanger the safe operation of an aircraft”. Section 125.409 also requires reporting of failures, malfunctions, or defects. Ifailure or malfunction will be obvious, but there are some failure modes related to uncontrollable high thrust that are reportable The following information is provided, as required by FAA Exemption No. 7798 to assist the operators in identifying reportable muncontrollable high thrust.The FAA has concluded that the loss of capability to control thrust due to a failure of the engine thrust control system may endaincludes any malfunctions having one or more of the following characteristics:• Auto-acceleration or uncommanded thrust change to higher power• Stuck thrust lever above idle power• Inability to reduce thrustAlthough some of these incidents may not appear to be safety related, documenting the events is important to ensure the preseand/or to identify failure conditions that must be corrected.When filing a report of such an event with the FAA, the operator is requested to include in the description of the event, one or m• “thrust control”• “no response to thrust lever”• “auto-acceleration”• “uncontrolled high thrust”

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In addition, the following information should be included in the report:• Event description• Flight Crew action• Maintenance action• List of affected or removed componentsReports should be submitted to the local representative of the FAA Administrator that handles the appropriate reporting respon125.409, and 135.415. In addition to filing reports with the FAA, it is recommended that a copy be sent to Boeing and to the en

E. AIRWORTHINESS LIMITATIONS – FUEL SYSTEMS

This section of the Airworthiness Limitations contains an FAA approved program of scheduled inspections and design limitation

incorporate into their maintenance program for this type design to meet the new standards and assumptions introduced by § 25Aviation Regulation (SFAR) No. 88. SFAR 88 - Fuel Tank System Fault Tolerance Evaluation Requirements and Title 14 Code § 25.981 - Fuel Tank Ignition Prevention require maintenance instructions, and control limitations for certain fuel tank critical deParagraph 2(a) of SFAR 88 and paragraph (b) of the new standard introduced by § 25.981 requires certain design approval ho(TCs) and Supplemental Type Certificates (STCs) of large transport airplanes to conduct a safety review of the fuel tank systemsafety review is to identify design features that may result in development of ignition sources in the fuel tank systems. Fuel sysLimitations (AWLs) are mandatory maintenance actions required to ensure that unsafe conditions identified by the safety review introduced into the fuel tank system as a result of configuration changes, repairs, alterations, or deficiencies in the maintenance operational life of the airplane. An AWL may be an Airworthiness Limitation Instruction (ALI) or a Critical Design Configuration 

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CDCCLs are a means of identifying certain design configuration features intended to preclude a fuel tank ignition source for the airplane. CDCCLs are mandatory and cannot be changed or deleted without the approval of the Seattle FAA ACO that is respomodel Type Certificate, or applicable regulatory agency. A critical fuel tank ignition source prevention feature may exist in the finstallation or in systems that, if a failure condition were to develop, could interact with the fuel system in such a way that an undevelop without this limitation. Strict adherence to configuration, methods, techniques, and practices as prescribed is required tthe CDCCL. Any use of parts, methods, techniques or practices not contained in the applicable CDCCL must be approved by tresponsible for the airplane model Type Certificate, or applicable regulatory agency.ALIs identify inspection tasks related to fuel tank ignition source prevention which must be done to maintain the design level of life of the airplane. These ALIs are mandatory and cannot be changed or deleted without the approval of the Seattle FAA ACOagency. Strict adherence to methods, techniques and practices as prescribed is required to ensure the ALI is complied with. Atechniques or practices not contained in these ALIs must be approved by the Seattle FAA ACO, or applicable regulatory agencUSE OF ALTERNATE TOOLSFor AWLs which require use of certain tools, use of alternate tools requires prior approval from the Seattle FAA ACO.EXCEPTIONAL SHORT-TERM EXTENSIONSSince AWL intervals are based on estimations of the probability of an event, an exceptional short-term extension for each fuel sdocument may be made without jeopardizing safety. The local regulatory authority (e.g. a Principle Maintenance Inspector) mexceptional short-term extensions before they take place using procedures established with the local regulatory authority in the “exceptional short-term extension” process is applicable to AWL intervals. It should not be confused with the operator’s “short-tnormal maintenance tasks described in the operators’ manuals and in the Flight Standards Handbook 8300.10.

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The Seattle FAA ACO has accepted that these exceptional short-term extensions may be granted without consultation with tha1. The term “exceptional short-term extension” is defined as an increase in a fuel system AWL interval that may be needed to 

unexpected situation. All AWLs listed in this section have been approved with an exceptional short-term extension of 30 da

2. Repeated use of extensions, either on the same airplane or on similar airplanes in an operator’s fleet, should not be used a

management practices. Exceptional short-term extensions must not be used for fleet AWL extensions.

After a fuel system AWL has experienced an exceptional short-term extension, the AWL interval will revert back to its interval li

Seattle FAA ACO must approve, prior to its use, any desired extension not explicitly listed above.The exceptional short-term extension listed above applies to airlines that fall under the United States FAA jurisdiction only. OpU.S. FAA jurisdiction should obtain interval extension approvals from their local regulatory agency.REGULATORY AGENCY APPROVALAny deviations from the published AWL instructions included in this document require approval from the Seattle FAA ACO. Thunder the United States FAA jurisdiction only and to airplanes registered in the U.S. All other operators should obtain approval regulatory agency for any deviations from the listed AWL instructions.AWL REVISION PROCESSIn the event that an AWL is revised, Boeing will prepare a revision to this document that will be approved by the Seattle FAA ACbe forwarded to all 757 operators and the Seattle FAA ACO.

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F. PAGE FORMAT: FUEL SYSTEMS AIRWORTHINESS LIMITATIONS

COLUMN EXPLANATIONAWL Number Each task is given a unique AWL Item Number. The first and second digits are the ATA Chapter Number.Task ALI = Airworthiness Limitation Instruction. These tasks are inspections that should be performed at the listed interv

CDCCL = Critical Design Configuration Control Limitation.

Interval Task frequencies are specified in terms of a usage parameter such as flight hours, cycles or calendar time.Applicability Airplane model applicability.

Description Description of the task to be performed or critical design configurations aspects that cannot be changed without vio

the design.

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G. AIRWORTHINESS LIMITATIONS – FUEL SYSTEM AWLs

AWL Number Task Interval Applicability Description

28-AWL-01 ALI 10 Yrs All External Wires Over Center Fuel Tank 

Concern: Potential for Wire chafing and arcing to Center Fuel Tank UppePerform a detailed inspection of the wire bundles routed over the center ffloor boards per AMM 28-11-00 to detect damaged clamps, wire chafing, contact with surface of the center fuel tank. If discrepancies are found, repPractices Manual, D6-54446.

28-AWL-02 CDCCL N/A All External Wires Over Center Fuel Tank 

Concern: Potential for Wire chafing and arcing to Center Fuel Tank UppeIf any maintenance is performed in the area under the floor boards and othe following:1. Maintain the existing wire bundle routing and clamping.2. Installation of any new wire bundles must be per Boeing Standard Wir3. All wire bundles over the center fuel tank are inspected per 28-AWL-0

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28-AWL-03 ALI 10 Yrs See Description Fuel Quantity Indicating System (FQIS) – Out of Tank Wiring Lightning S

Concern: Potential for Lightning induced voltages on the FQIS wiring to ePerform the following inspection to ensure the functional integrity of the Ftermination per Boeing AMM 20-55-54:757-200 Airplanes with BF Goodrich without individually shielded wiring tlightning protection:

Left Main Tank-Hi-Z: The loop resistance shall not exceed 506 millioE3-4 shelf) and the wire bundle number W4024.Left Main Tank-Lo-Z: The loop resistance shall not exceed 282 milliE3-4 shelf) and the wire bundle number W4024.Right Main Tank-Hi-Z: The loop resistance shall not exceed 572 m(near E3-4 shelf) and the wire bundle number W4026.Right Main Tank-Lo-Z: The loop resistance shall not exceed 326 mi(near E3-4 shelf) and the wire bundle number W4026.Left Center Tank-Hi-Z: The loop resistance shall not exceed 183 m(near E3-4 shelf) and the wire bundle number W4024.Right Center Tank-Hi-Z: The loop resistance shall not exceed 200 (near E3-4 shelf) and the wire bundle number W4026.Left Main Tank Densitometer Overbraid: The loop resistance shall npressure seal and the wire bundle number W4020.Right Main and Center Tank Densitometer Overbraid: The loop res48 milliohms near the pressure seal and the wire bundle number W

757-200 Airplanes with BF Goodrich with individually shielded wiring on thlightning protection.

Left Main Tank-Hi-Z: The loop resistance shall not exceed 486 milliE3-4 shelf) and the wire bundle number W4024.

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AWL Number Task Interval Applicability Description

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28-AWL-03,

Continued

See Description Left Main Tank-Lo-Z: The loop resistance shall not exceed 280 milli

E3-4 shelf) and the wire bundle number W4024.Right Main Tank-Hi-Z: The loop resistance shall not exceed 608 m(near E3-4 shelf) and the wire bundle number W4026.Right Main Tank-Lo-Z: The loop resistance shall not exceed 336 m(near E3-4 shelf) and the wire bundle number W4026.Left Center Tank-Hi-Z and Lo-Z: The loop resistance shall not exceD42224P (near E3-4 shelf) and the wire bundle number W4024.Right Center Tank-Hi-Z and Lo-Z: The loop resistance shall not excD42226P (near E3-4 shelf) and the wire bundle number W4026.Left Main Tank Densitometer Shield: The loop resistance shall not eD41272P (near E3-4 shelf) and the wire bundle number W4020.Right Main and Center Tank Densitometer Shield: The loop resistafor connector D41276P (near E3-4 shelf) and the wire bundle numb

757-300 airplanes with BF Goodrich (All):

Left Main Tank-Hi-Z: The loop resistance shall not exceed 600 milliE3-4 shelf) and the wire bundle number W4024.Left Main Tank-Lo-Z: The loop resistance shall not exceed 341 milliE3-4 shelf) and the wire bundle number W4024.Right Main Tank-Hi-Z: The loop resistance shall not exceed 700 m(near E3-4 shelf) and the wire bundle number W4026.Right Main Tank-Lo-Z: The loop resistance shall not exceed 382 m(near E3-4 shelf) and the wire bundle number W4026.Left Center Tank-Hi-Z and Lo-Z: The loop resistance shall not exceD42224P (FWD Cargo) and the wire bundle number W4024.Right Center Tank-Hi-Z and Lo-Z: The loop resistance shall not excD42226P (FWD Cargo) and the wire bundle number W4026.

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AWL Number Task Interval Applicability Description

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28-AWL-03,

Continued

See Description Left Main Tank Densitometer: The loop resistance shall not exceed 

D41272P (FWD Cargo) and the wire bundle number W4020.Right Main and Center Tank Densitometer: The loop resistance shaconnector D41276P (FWD Cargo) and the wire bundle number W40

757-200 airplanes with Honeywell, with 20 gauge HI-Z wire, and without Hwire. This would be a delivered airplane configuration, or a configuration Bulletin 757-28-0015, but not with Service Bulletin 757-28-0020 installed.

Right Main and Center Tank Lo-Z Shield: The loop resistance shall connector D41620P or D41270P (near the E3-4 shelf) and the wire Right Main Tank Hi-Z Shield: The loop resistance shall not exceed D42222P (near the E3-4 shelf) and the wire bundle number W4218 Right Main Tank Lo-Z Shield: The loop resistance shall not exceed D41196P or D41396P (near the vapor seal) and the wire bundle nuRight Main Tank Lo-Z Shield: The loop resistance shall not exceed (spar connector) and the wire bundle number W3462.Left Main and Center Tank Lo-Z Shield: The loop resistance shall nconnector D41636P or D41268P (near the E3-4 shelf) and the wire Left Main Tank Hi-Z Shield: The loop resistance shall not exceed 1D42220P (near the E3-4 shelf) and the wire bundle number W4206 Left Main Tank Lo-Z Shield: The loop resistance shall not exceed 10(near the vapor seal) and the wire bundle number W3342 or W3372Left Main Tank Lo-Z Shield: The loop resistance shall not exceed 4(spar connector) and the wire bundle number W3326.Left Center Tank Hi-Z Shield: The loop resistance shall not exceed D42224P (near the E3-4 shelf) and the wire bundle number W4206 Right Center Tank Hi-Z Shield: The loop resistance shall not exceed D42226P (near the E3-4 shelf) and the wire bundle number W4218 

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AWL Number Task Interval Applicability Description

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28-AWL-03,

Continued

See Description 757-200 airplanes with Honeywell, with 18 gauge HI-Z wire, without HI-Z d

a delivered airplane configuration or a configuration after incorporation of 

Right Main and Center Tank Lo-Z Shield: The loop resistance shall connector D41620P or D41270P (near the E3-4 shelf) and the wire Right Main Tank Hi-Z Shield: The loop resistance shall not exceed D42222P (near the E3-4 shelf) and the wire bundle number W4218 Right Main Lo-Z Shield: The loop resistance shall not exceed 100 mD41396P (near the vapor seal) and the wire bundle number W3424 Right Main Tank Lo-Z Shield: The loop resistance shall not exceed (spar connector) and the wire bundle number W3462.Left Main and Center Tank Lo-Z Shield: The loop resistance shall nconnector D41636P or D41268P (near the E3-4 shelf) and the wire Left Main Tank Hi-Z Shield: The loop resistance shall not exceed 52(near the E3-4 shelf) and the wire bundle number W4206 or W4024Left Main Lo-Z Shield: The loop resistance shall not exceed 101 m(near the vapor seal) and the wire bundle number W3342 or W3372Left Main Tank Lo-Z Shield: The loop resistance shall not exceed 4(spar connector) and the wire bundle number W3326.Left Center Tank Hi-Z Shield: The loop resistance shall not exceed D42224P (near the E3-4 shelf) and the wire bundle number W4206 Right Center Tank Hi-Z Shield: The loop resistance shall not exceeD42226P (near the E3-4 shelf) and the wire bundle number W4218 

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28-AWL-03,

Continued

See Description 757-200 airplanes with Honeywell, with 20 gauge wire and, with HI-Z disc

delivered airplane configuration or a configuration without incorporation oBulletins: 757-28-020 or 757-28-0015.

Right Main and Center Tank Lo-Z Shield: The loop resistance shall connector D41620P or D41270P (near the E3-4 shelf) and the wire Right Main Tank Hi-Z Shield: The loop resistance shall not exceed D42222P (near the E3-4 shelf) and the wire bundle number W4218 Right Main Tank Hi-Z Shield: The loop resistance shall not exceed D41398P or D42334P or D41396P (near the vapor seal) and the wirRight Main Tank Hi-Z Shield: The loop resistance shall not exceed 7(near vapor seal) or at D2818 (spar connector) and the wire bundle Right Main Tank Lo-Z Shield: The loop resistance shall not exceed D41196P or D41396P (near vapor seal) and the wire bundle numbeRight Main Tank Lo-Z Shield: The loop resistance shall not exceed (spar connector) and the wire bundle number W3462.Left Main and Center Tank Lo-Z Shield: The loop resistance shall nconnector D41636P or D41268P (near the E3-4 shelf) and the wire Left Main Tank Hi-Z Shield: The loop resistance shall not exceed 72(near the E3-4 shelf) and the wire bundle number W4206.Left Main Tank Hi-Z Shield: The loop resistance shall not exceed 44or D41194P (near the vapor seal) and the wire bundle number W34Left Main Tank Hi-Z Shield: The loop resistance shall not exceed 82 or D41392J (near disconnect AW1333) or D2792 (spar connector) aLeft Main Tank Lo-Z Shield: The loop resistance shall not exceed 1D41192P (near disconnect AW1333) and the wire bundle number WLeft Main Tank Lo-Z Shield: The loop resistance shall not exceed 4(spar connector) and the wire bundle number W3326.

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AWL Number Task Interval Applicability Description

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28-AWL-03,

Continued

See Description Left Center Tank Hi-Z Shield: The loop resistance shall not exceed 

D42224P (near the E3-4 shelf) and the wire bundle number W4206 Right Center Tank Hi-Z Shield: The loop resistance shall not exceed D42226P (near the E3-4 shelf) and the wire bundle number W4218 

757-200 airplanes with BF Goodrich converted from Honeywell system. brackets for some of the tank unit signal wiring. All have 18 gauge HI-Z wHI-Z wires.

Right Main and Center Tank Lo-Z Shield: The loop resistance shall connector D41620P or D41270P (near the E3-4 shelf) and the wire Right Main Tank Hi-Z Shield: The loop resistance shall not exceed D42222P (near the E3-4 shelf) and the wire bundle number W4218 Right Main Tank Lo-Z Shield: The loop resistance shall not exceed 8or D41396P (near the vapor seal) and the wire bundle number W34Right Main Tank Lo-Z Shield: The loop resistance shall not exceed (spar connector) and the wire bundle number W3462.Left Main and Center Tank Lo-Z Shield: The loop resistance shall nconnector D41636P or D41268P (near the E3-4 shelf) and the wire Left Main Tank Hi-Z Shield: The loop resistance shall not exceed 52(near the E3-4 shelf) and the wire bundle number W4206 or W4024Left Main Tank Lo-Z Shield: The loop resistance shall not exceed 1D41192P (near the E3-4 shelf) and the wire bundle number W3342 Left Main Tank Lo-Z Shield: The loop resistance shall not exceed 4(spar connector) and the wire bundle number W3326.Left Center Tank Hi-Z Shield: The loop resistance shall not exceed D42224P (near the E3-4 shelf) and the wire bundle number W4206 Right Center Tank Hi-Z Shield: The loop resistance shall not exceed D42226P (near the E3-4 shelf) and the wire bundle number W4218 

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AWL Number Task Interval Applicability Description

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28-AWL-03,

Continued

See Description Left Main Tank Densitometer Overbraid: The loop resistance shall 

Pressure Seal and the wire bundle number W4020 and overbraid teRight Main and Center Tank Densitometer Overbraid: The loop res48 milliohms near Pressure Seal and the wire bundle number W402GD-LTNG.

28-AWL-04 CDCCL N/A All Fuel Quantity Indicating System (FQIS) – Out of Tank Wiring Lightning S

Concern: Potential for Lightning induced voltages on the FQIS wiring to eIf any maintenance is performed on the FQIS wire bundle in the un-pressubody pressure seal, verify the following: 1. Presence of shielded wiring.2. The shield ground is terminated per the Boeing SWPM 20-10-15.3. The installation is inspected per 28-AWL-03 if the wire bundle shield ( is repaired or replaced.

28-AWL-05 CDCCL N/A All Fuel Quantity Indicating System (FQIS) – Out of Tank Wiring Installation 

Concerns: Potential for hot shorts and EMI induced voltages on the FQIS Routing and installation of any new wiring must use wire types BMS 13-4not be within a 2-inch radius of the FQIS wiring. Under single failures of greater than 1⁄2 inch must be maintained from FQIS wiring.

28-AWL-06 CDCCL N/A All Fuel Quantity Indicating System (FQIS) – Repair of Processor Unit 

Concern: Potential for maintenance error during FQIS processor repair.The FQIS processor is designed to limit the levels of energy, voltage, curFQIS circuit to intrinsically safe levels in order to preclude the potential of fuel tank.Repair and overhaul of FQIS processor units must be per the Goodrich (Vand IPC 28-41-68 Revision 4, or Honeywell (V58960) CMM 28-41-37 Rev7, or later revisions of these CMMs/IPCs that have been approved by the 

AWL Number Task Interval Applicability Description

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BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

757 MAINTENANCE PLANNING DATA

28-AWL-07 CDCCL N/A All Fuel Quantity Indicating System (FQIS) – Repair of In-Tank Hardware (T

and Densitometers)Concern: Potential for maintenance error during repair of in-tank hardwardensitometers). Arc gaps may develop that could result in an ignition souRepair and overhaul of FQIS tank units, compensators and densitometer(V89305) CMM 28-40-56 Revision 4, CMM 28-40-62 Revision 3, CMM 28(V65507) CMM 28-41-18 Revision 6, CMM 28-41-09 Revision 6, or later been approved by the Seattle FAA ACO.

28-AWL-08 CDCCL N/A All Fuel Quantity Indicating System (FQIS) – Repair or Replacement of In-Ta

Concern: Potential for error during repair or replacement of in-tank wire hcould result in an ignition source inside the fuel tank.Repair and overhaul of FQIS in-tank wire harness must be per Boeing SWInstallation of FQIS in-tank wire harness must be per Boeing AMM 28-41Installation of the FQIS In-tank Wire Harness must be per Boeing AMM 2between wires and structure must be greater than 0.125 inches. Verify thpenetration receptacle:1. The mating surface of the tank wiring harness on the front spar is clea2. New O-ring(s) are installed. 3. The Jamnuts are tightened to a torque as specified in the Boeing AMM 4. Sealant is installed per instruction in the Boeing AMM Task 28-41-09.

AWL Number Task Interval Applicability Description

DEC 2008
757 MAINTENANCE PLANNING DATA

D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

28-AWL-09 CDCCL N/A All Lightning Protection – Hydraulic Line Fuel Tank Penetration 

Concern: Potential for arcing or sparking inside the tank at the interface bspar during a lightning strike event.The following design features must be maintained per Boeing AMM 29-1removed and replaced:1. Verify electrical fay surface bond from bulkhead fitting to structure out

(1 milliohm) or less,

2. Install fillet seal on the fitting to the tank wall interface outside the tank3. Install full bodied fillet seal encapsulating the fitting to the tank wall int4. Verify an electrostatic bonding jumper exists between the structure an

inside the tank, and

5. Verify electrical bond from structure to the Hydraulic Heat Exchanger 

(2.5 milliohms) or less if the bonding jumper was removed and replace

AWL Number Task Interval Applicability Description

DEC 2008
D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

757 MAINTENANCE PLANNING DATA

28-AWL-10 CDCCL N/A 757-200 and 

-300 airplanes Line Numbers 1042 and 

on and airplanes 

that have 

incorporated 

Service Bulletins 

757-28A0076 or 

757-28A0077

Lightning Protection – Engine Fuel Feed Line Tank PenetrationConcern: Potential for arcing or sparking inside the tank at the interface bspar during a lightning strike event.The following design features must be maintained per Boeing AMM 28-22attached tubing are removed and replaced:1. Verify electrical fay surface bond from the fuel hose end fitting to the a

0.0005 ohms (0.5 milliohms) or less,

2. Install fillet seal around the entire perimeter of the washer and jam nut 

front spar,

3. Install full bodied fillet seal around the entire perimeter of the washer, 

ferrule of the hose assembly end fitting on the aft side of the front spa

4. Install full bodied fillet seal around the entire perimeter of the washer, 

ferrule of the hose assembly end fitting on the forward side of the dry 

5. Install full bodied fillet seal around the entire perimeter of the washer, 

the exposed part of the hose assembly end fitting, the entire surface oonto the tube assembly on the aft side of the dry bay wall (tank side), 

6. Verify an electrostatic bonding jumper exists between the structure and 

assembly end fitting inside the tank, and

7. Verify electrical bond from structure to first tube mating with the hose 

is 0.010 ohms (10 milliohms) or less if the bonding jumper was remov

28-AWL-11 CDCCL N/A All Lightning, Fault Current or Hot Short Protection – Fuel Tank Penetrations

Concern: Potential for arcing or sparking inside the tank at a conductive as a result of electrical fault currents or lightning strike events due to insuelectrical path. Addition of any new penetrations to the fuel tanks (such as adding a brackor change to the design features of the existing equipment penetrations sump drain valves, fueling manifold, fuel temperature sensor, and motor plate) requires approval by the Seattle FAA ACO.

AWL Number Task Interval Applicability Description

DEC 2008
757 MAINTENANCE PLANNING DATA

D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

28-AWL-12 CDCCL N/A All AC and DC Electrical Fuel Tank Pump Maintenance

Concern: Potential for maintenance error during pump overhaul. Fuel puprevention means (i.e., flame arrestor, thermal fuses, materials, leadwire maintained if pump is overhauled.Repair and overhaul of AC Fuel Pumps must be per Crane (V81982) CMM 06 Revision 6, CMM 28-22-08 Revision 4, CMM 28-22-09 Revision 2, or have been approved by the Seattle FAA ACO.Repair and overhaul of DC Fuel Pump must be per Intertechnique (VF05later revision of this CMM that has been approved by the Seattle FAA AC

28-AWL-13 CDCCL N/A All AC Fuel Pump Fault Current Bonding Strap Installation 

Concern: Potential for fault current path through the pump housing to strfaults internal to the fuel pump motor impeller are by design routed througthe bonding straps on the front face of the motor impeller assembly to strbonding straps ensure that fault currents are conducted to structure outsiand/or GFI has had time to remove power from the pump.The following features must be maintained during pump replacement per 1. Install two bonding straps between the pump motor impeller end-cap a2. Verify Motor Impeller bonding resistance to structure is 0.0004 ohms (

28-AWL-14 ALI 10 Yrs All 757-200/-300 

airplanes prior to 

Line Number 865

Center Wing Tank Fueling Shutoff Valve Actuator – Fault Current Bond Concern: Potential for arcing or filament heating inside the center wing fu

Verify electrical bond from the valve body studs protruding through the re0.012 ohms (12 milliohms) or less per Boeing AMM 28-21-02. Accomplis28-21-02 if the measured resistance is greater than 0.012 ohms (12 millio1. Restore the valve electrical fay surface bond inside the tank to 0.0025 2. Install a fillet seal around the entire perimeter of the gaskoseal and the Verification of existence or addition of the fillet seal per item “2” above anrequirement 0.012 ohm (12 milliohms) or less eliminates the repetitive ins

AWL Number Task Interval Applicability Description

DEC 2008
D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

757 MAINTENANCE PLANNING DATA

28-AWL-15 CDCCL N/A All Center Wing Tank Fueling Shutoff Valve Actuator – Fault Current Bond 

Concern: Potential for arcing or filament heating inside the center wing fu

The following features must be maintained per Boeing AMM 28-21-02 if tremoved and replaced:1. Verify electrical fay surface bond between the valve body to structure 

(2.5 milliohms) or less,

2. Install fillet seal around the entire perimeter of the gaskoseal and the The following feature must be maintained per Boeing AMM 28-21-12 if thand replaced:1. Install a bonding jumper bonding the valve control unit (actuator) to th

resistance is 0.008 ohms (8 milliohms) or less; applicable to 757-200/-865 and on.

28-AWL-16 CDCCL N/A All Fuel Tank Access Doors – Lightning Protection Bond

Concern: Potential for arcing or sparking inside the tank at the interface bstructure as a result of a direct strike or conducting currents through the wThe following features must be maintained during fuel tank access door i28-11-01, 28-11-02 and 28-11-03 as applicable: Verify presence of a phenolic strip positioned around the outermost peripwing skin inside the tank.Do a check of the knitted aluminum mesh gasket for serviceability and reApply anti-corrosion compound (grease or CIC) to both sides of the knitteInstall the prepared knitted aluminum mesh gasket between the outside faestablish the electrical conductivity between the access door and the winfasteners torqued to that specified in the applicable AMM. Not applicable to Access Doors 543AB, 543BB, 643AB & 643BB (Surge Pressure Relief Valve and NACA Vent Scoop).

AWL Number Task Interval Applicability Description

DEC 2008
757 MAINTENANCE PLANNING DATA

D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

28-AWL-17 CDCCL N/A All Surge Tank Access Doors (543AB and 643AB) – Lightning Protection Bo

Concern: Potential for arcing or sparking inside the tank at the interface bstructure as a result of a direct strike or conducting currents through the wDuring surge tank access door installation, perform the following actions Verify presence of a phenolic strip positioned around the outermost peripwing skin inside the tank.Maintain the electrical fay surface bond between the pressure relief valve (10 milliohms) or less if the valve is removed and re-installed or replaced Do a check of the knitted aluminum mesh gasket for serviceability and reApply anti-corrosion compound (grease or CIC) to both sides of the knitteInstall the prepared knitted aluminum mesh gasket between the outside faestablish the electrical conductivity between the access door and the winfasteners torqued to that specified in the Boeing AMM.

28-AWL-18 CDCCL N/A All Surge Tank Access Doors (543BB and 643BB) – Lightning Protection Bo

Concern: Potential for arcing or sparking inside the tank at the interface bstructure as a result of a direct strike or conducting currents through the wDuring surge tank access door installation, perform the following actions Clean the countersinks on the door, Maintain the electrical fay surface bond between the housing of the vent ohms (2.5 milliohms) or less if the housing of the vent flame arrestor is reper Boeing AMM 28-13-05, andInstall door using the same part number conductive fasteners and torque Boeing AMM. 

28-AWL-19 CDCCL N/A All Resetting Tripped Fuel Pump Circuit Breakers or Ground Fault Interrupte

Concern: Potential for arcing or sparking inside the tank between fuel puoutside the tank between pump wiring and structure in flammable leakagVerify it is safe to reset the Circuit Breaker(s) or GFI(s) by following the aprocedures. The fault(s) that resulted in circuit breaker or GFI trip must b

to reset.

AWL Number Task Interval Applicability Description

DEC 2008
D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

757 MAINTENANCE PLANNING DATA

28-AWL-20 ALI 1 Yr 757 airplanes that 

have incorporated 

Service Bulletins 

757-28A0081 or 

757-28A0082.

Center Tank Fuel Boost Pump Automatic Shutoff SystemConcern: Dry running the center tank fuel pumps has the potential for sindeveloping at the pump inlet due to either frictional heating or sparking as pump rotating elements, rotating elements contacting stationary parts, or contamination or failure.The automatic shutoff system is installed and designed to limit continuou15 seconds. The following test is required in order to protect against latent faults:Functionally check the center tank Fuel Boost Pump Automatic Shutoff S

28-AWL-21 ALI 1 Yr 757 airplanes that 

have incorporated 

Service Bulletins 

757-28A0078 or 

757-28A0079.

Boost Pump Ground Fault Interrupter (GFI)Concern: Potential for pump housing burn-through, either internal or extemajor arcing due to electrical failure (i.e., damaged electrical connector, shousing/end cap shorting). The GFI is designed to detect electrical faults and open the circuit prior to following maintenance check is required in order to ensure continued funOperationally check the GFI of all AC Fuel Tank Boost Pumps per Boeing 

28-AWL-22 CDCCL N/A 757 airplanes that 

have incorporated 

Service Bulletin 

757-28A0085.

Fuel Quantity Indicating System (FQIS) – Installation of Center Fuel Tank 

Concern: Potential for wire to wire hot short voltages on the center tank fenter the fuel tank. The FQIS HSP is designed to prevent wire to wire external hot short voltawhere it may cause an ignition. The following features must be maintaineper Boeing AMMs 28-41-24 and 28-41-25:1. Verify the bonding straps are installed per AMM task.2. Verify the bonds from HSP to spar web is 0.0025 ohms (2.5 milliohm) 3. A new unit must be used.The HSP unit is not repairable.

AWL Number Task Interval Applicability Description

DEC 2008
757 MAINTENANCE PLANNING DATA

D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

28-AWL-23 CDCCL N/A 757 airplanes that 

have incorporated 

SB 757-28A0088

Lightning and Fault Current Protection – Motor Operated Valve (MOV) AcConcern: Potential for arcing or sparking inside the fuel tank at a conducinterface as a result of electrical fault current or lightning events.The following design features must be maintained per Boeing AMM 28-2228-22-12, 28-26-01, or 28-26-02 during actuator, index plate, or adapter 1. Maintain the following if the Spar Valve, Crossfeed Valve, or Defuel V

removed and replaced:

a. Verify electrical fay surface bond resistance between the adapte

0.0005 ohms (0.5 milliohms) or less.

b. Install fillet seal around the periphery of the adapter plate and thc. Wet install and cap seal the four bolts that attach the adapter pla

fillet seal around the edge of the hole and on the stationary part 

d. Install sealed electrical fay surface bond between the serrated m

and the adapter plate. Wet install the index plate screws using s

e. Install sealed electrical fay surface bond between the mating su

plate. Wet install the actuator screws using same sealant.

f. With the bonding jumper and the electrical connector not installe

resistance between the actuator upper housing and the spar weor less.

g. Prior to attachment of the bonding jumper to the actuator, verify 

between the loose end of the bonding jumper and the stiffener is or less.

h. Attach the bonding jumper to the upper housing of the actuator u

bond and verify electrical bonding resistance between the actuabonding jumper terminal is 0.001 ohms (1 milliohms) or less.

2. Maintain the following if the Spar Valve, Crossfeed Valve, or Defuel Va

and replaced:

a. Install sealed electrical fay surface bond between the serrated m

and the adapter plate. Wet install the index plate screws using s

b. Install sealed electrical fay surface bond between the mating su

plate. Wet install the actuator screws using same sealant. 

c. With the bonding jumper and the electrical connector not installe

resistance between the actuator upper housing and the spar weor less.

(Continued on next page)

AWL Number Task Interval Applicability Description

DEC 2008
D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

757 MAINTENANCE PLANNING DATA

28-AWL-23,

Continued

Lightning and Fault Current Protection – MOV Actuator (Continued)

d. Prior to attachment of the bonding jumper to the actuator, verify 

between the loose end of the bonding jumper and the stiffener is or less.

e. Attach the bonding jumper to the upper housing of the actuator u

bond and verify electrical bonding resistance between the actuabonding jumper terminal is 0.001 ohms (1 milliohms) or less.

3. Maintain the following if the Spar Valve, Crossfeed Valve, or Defuel V

replaced:

a. Install sealed electrical fay surface bond between the mating su

plate. Wet install the actuator screws using the same sealant.

b. With the bonding jumper and the electrical connector not installe

resistance between the actuator upper housing and the spar weor less.

c. Prior to attachment of the bonding jumper to the actuator, verify 

between the loose end of the bonding jumper and the stiffener is or less.

d. Attach the bonding jumper to the upper housing of the actuator u

bond and verify electrical bonding resistance between the actuabonding jumper terminal is 0.001 ohms (1 milliohms) or less.

The following design features must be maintained per Boeing AMM 28-25replacement:1. Maintain the following if the APU Shutoff Valve actuator is removed a

a. Prior to attachment of the bonding jumper to the actuator, verify 

between the loose end of the bonding jumper and the spar web or less.

b. Attach the bonding jumper to the upper housing of the actuator u

bond and verify electrical bonding resistance between the actuabonding jumper terminal is 0.001 ohms (1 milliohms) or less.

AWL Number Task Interval Applicability Description

DEC 2008
757 MAINTENANCE PLANNING DATA

D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

28-AWL-24 CDCCL N/A 757 airplanes that 

have incorporated 

SB 757-28A0088

Motor Operated Valve (MOV) Actuator – RepairConcern: Potential for arcing or sparking inside the fuel tank at a conducinterface as a result of lightning or electrical fault current event. An electrshaft is intended to disconnect the output shaft electrically from the motoground path structure.To verify the integrity of the electrical isolation feature, conduct the followCMM 28-20-21:A Dielectric Strength test on the completed actuator assembly shall be peRMS, 60 Hz for one (1) minute between any mounting foot of the actuator shall be no evidence of disruptive discharge in the form of leakage curren3000V test is a bench test only and must not be performed on the aircraft

28-AWL-25 ALI 6 Yrs 757 airplanes that 

have incorporated 

Service Bulletin 

757-28A0088

Lightning & Fault Current Protection – Motor Operated Valve (MOV) ActuConcern: Potential for arcing or sparking inside the fuel tank at a conducinterface as a result of lightning or electrical fault current event.Perform the following functional check (per Boeing AMM 28-22-11, 28-22integrity of the Spar Valve, Crossfeed Valve, and Defuel Valve actuator ea. With the actuator electrical connector and the bonding jumper disco

resistance between the connector flange and the spar web is 0.010 

b. Attach the bonding jumper to the upper housing of the actuator usin

bond and verify electrical bonding resistance between the actuator jumper terminal is 0.001 ohms (1 milliohm) or less.

Perform the following functional check (per Boeing AMM 28-25-11) to ensValve actuator electrical bonding path:a. With the actuator electrical connector disconnected, verify electrical 

connector flange and the spar web is 0.010 ohms (10.0 milliohms) o

AWL Number Task Interval Applicability Description

DEC 2008
D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

757 MAINTENANCE PLANNING DATA

28-AWL-26 ALI 1 Yr Airplanes that have 

incorporated 

Service Bulletin 

757-28A0105

Center Tank Fuel Boost Pump Power Failed On Protection SystemConcern: Dry running the center tank fuel pumps has the potential for sindeveloping at the pump inlet due to either frictional heating or sparking as pump rotating elements, rotating elements contacting stationary parts, or contamination or failure.The power failed on protection system is installed and designed in order (i.e., wiring faults or a welded fuel pump control relay) keeping power on pump control switch is positioned to OFF.The following test is required in order to protect against latent faults:Verify continued functionality of the center tank fuel boost pump Power FAMM 28- 22-00.

AWL Number Task Interval Applicability Description

DEC 2008
757 MAINTENANCE PLANNING DATA

D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

H. AIRWORTHINESS LIMITATIONS – NITROGEN GENERATION SYSTEM (NGS) ALIs and CDCCLs

The following list of AWLs (ALIs and CDCCLs) contain FAA-approved scheduled inspections for operators to incorporate into th

for this type design to meet the requirements for the introduction of the Flammability Reduction Means (FRM) Nitrogen GeneraFAA operational rule change E8-16084 Final Flammability Rule requires maintenance instructions and control limitations for ceconfigurations. § 25.981(d) also requires CDCCLs to preclude ignition sources inside the fuel tank that may be introduced by thE8-16084, Final Flammability Rule, Paragraph III(F), Section 7, Identification of Airworthiness Limitations: Paragraph M25.4(a) to comply with Paragraph M25.1, AWLs must be identified for all maintenance or inspection tasks required to identify failures of FRM that are needed to meet Paragraph M25.1. NGS AWLs are mandatory maintenance actions that ensure that unsafe condfailures do not occur or are not introduced into the airplane as a result of configuration changes, repairs, alterations, or deficienmaintenance program throughout the operational life of the airplane.

NOV 2010
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757 MAINTENANCE PLANNING DATA

AWL Number Task Interval Applicability Description

47-AWL-01 CDCCL N/A 757 airplanes that 

have incorporated 

Service Bulletin 

757-47-0001

Lightning Protection – NGS Nitrogen Enriched Air (NEA) Distribution Line Concern: Potential for arcing or sparking at the interface between the bullightning strike event. The following must be maintained if the bulkhead fitand replaced or reinstalled (refer to Boeing AMM 47-21-05):1. Install the same part number bulkhead fitting.2. Verify electrical fay surface bond between the bulkhead fitting and the 

is 0.0005 ohms or less,

3. Install full-bodied fillet seal encapsulating the first coupling connectin

inside the tank and that part of the bulkhead fitting inside the tank,

4. Verify electrical bond from structure to first tube mating with the bulk

(10 milliohms) or less.

Note: The bulkhead fitting is a special part which has an integral flame arequires approval by the Seattle FAA ACO.

47-AWL-02 CDCCL N/A 757 airplanes that 

have incorporated 

Service Bulletin 

757-47-0001

Center Fuel Tank Vent System – Auxiliary TanksConcern: The addition of an Auxiliary Fuel Tank System via a Supplemereduce the effectiveness of the NGS resulting in an increase in flammabiThe NGS installation is designed to provide the proper level of nitrogen to reduce the fleet wide average flammability exposure to levels equal to thatank installations typically transfer fuel and ullage gases to and from the cAny new STC design auxiliary tank system that communicates ullage diremust not significantly affect the performance of the FRS. All new STC aureviewed and approved by the Seattle FAA ACO. Refer to Boeing AMM ASystem and Fuel Venting System.

NOV 2010
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D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

AWL Number Task Interval Applicability Description

47-AWL-03 CDCCL N/A 757 airplanes that 

have incorporated 

Service Bulletin 

757-47-0001

Lightning Protection – NGS NEA Distribution Line Fuel Tank PenetrationConcern: Potential for arcing, sparking or filament heating inside the tank dielectric isolator hose and the NEA tubing during a lightning strike eventThe NGS installation is designed to prevent lightning currents from enteriadding a dielectric isolator hose in the forward leading edge fairing area Nmust be maintained if the dielectric isolator hose or attached tubing are reBoeing AMM 47-21-00).Note: The isolator hose is a special part with dielectric properties for lightpart requires approval by the Seattle FAA ACO.

47-AWL-04 ALI 17,300 HRS 757 airplanes that 

have incorporated 

Service Bulletin 

757-47-0001

NGS – NEA Distribution Ducting InspectionConcern: The NEA Distribution System ducting outside the fuel tank may without reaching the fuel tank, resulting in the fuel tank not reaching requInspect the NEA distribution lines from the ASU to the fuel tank front spar Boeing AMM 47-21-00).

47-AWL-05 ALI 17,300 HRS 757 airplanes that 

have incorporated 

Service Bulletin 

757-47-0001

NGS – Cross-Vent Check Valve – Operational CheckConcern: The Cross-Vent Check Valve may fail open, latently allowing adiluting the nitrogen rich environment created by the NGS.Operationally check the Cross-Vent Check Valve by accessing the left wivalve opens and closes (refer to Boeing AMM 47-21-05).

47-AWL-06 CDCCL N/A 757 airplanes that 

have incorporated 

Service Bulletin 

757-47-0001

Industry Fleet Average Flammability ExposureConcern: NGS performance is dependent on industry descent times. Indmay result in NGS performance that does not meet FAA requirements.Fleet Average flammability exposure for the fuel tanks with flammability rbe maintained in accordance with 14 CFR Part 25, Appendix M. Boeing and, if necessary to maintain compliance, will publish service informationinformation, this CDCCL requires either that operators implement these Fthat operators implement other design changes or operational proceduraAircraft Certification Office to maintain compliance with 14 CFR Part 25, ANOTE: This CDCCL does not require individual operators to monitor descmonitor US descent statistics and provide any needed service instructionincreasing flammability exposure above permissible levels, this CDCCL rfuture Boeing published service instructions denoted to maintain compliaapproved actions, within the compliance times stated in the service instru

NOV 2010
D622N001-9

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757 MAINTENANCE PLANNING DATA

I. CERTIFICATION MAINTENANCE REQUIREMENTS (CMRs)

Maintenance requirements arising from aircraft certification activities are described in FAR 25.1309 and AC 25.1309. Independ

process, these CMRs are developed as part of the aircraft systems safety analyses required for aircraft certification. CMR Tassystem probabilities and failure effects are not expected to fall within an acceptable range without a periodic maintenance requThere are two categories of CMRs. The first are those tasks associated with items critical to safety of flight; these "critical" systexpected probability of failure within the "extremely improbable" range. The second category of CMRs are those tasks associasafety of flight; these "essential" systems must have an expected probability of failure within the "improbable" range.The following notes apply to all CMR Tasks:1. CMRs are a part of the aircraft's certification basis.2. Approval of CMRs and escalation of CMR Task Frequencies are the exclusive responsibility of the Seattle FAA ACO.3. There shall be no short-term escalation of CMRs (except as provided in Advisory Circular AC 25-19 Certification Maintenan4. There shall be no reliability program escalation of CMRs (except as provided in Advisory Circular AC 25-19 Certification Ma5. There shall be no Flight Standards inspector escalation of CMRs (except as provided in Advisory Circular AC 25-19 Certific

Requirements).

NOV 2010
757 MAINTENANCE PLANNING DATA

D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

J. PAGE FORMAT: CERTIFICATION MAINTENANCE REQUIREMENTS (CMRs)

COLUMN EXPLANATIONMPD ITEM NUMBER Each task in the MPD is identified with a unique number. The first and second digits are the ATA Number. The rest 

MPD Sequence Number.

TASK MSG-3 TASK CATEGORIES

LUB = LUBRICATIONSVC = SERVICINGVCK = VISUAL CHECKOPC = OPERATIONAL CHECKFNC = FUNCTIONAL CHECKRST = RESTORATIONDIS = DISCARD

Any act of consumable replenishment for the purpose of maintaining inheAny act of consumable replenishment for the purpose of maintaining inheA visual failure finding task to determine if an item is fulfilling its intended quantitative tolerances.A failure finding task to determine if an item is fulfilling its intended purpostolerances.A quantitative check to determine if one or more functions of an item perfa potential failure finding task.Reworking, replacement of parts or cleaning necessary to return an item The removal and replacement of an item.

CMR INTERVAL Task intervals are specified in terms of flight hours, cycles, or calendar time. If the threshold (the first interval listed

interval listed underneath is the repeat interval.

ZONE Airplane Zone Number (see Zone Diagrams, MPD Appendix A) where task is performed.ACCESS Access Panel/Door Number (see Access Panel/Door illustrations, MPD Appendix A) required to be opened to perfo

NOV 2010
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757 MAINTENANCE PLANNING DATA

APPLICABILITY APL ENG

Applicable Airplane Model and Engine. "Note" refers to an explanation under the task description.APLALL = All 757 Airplanes300 = 757-300 AirplanesNOTE = Airplane Applicability Note

ENGINEALL = All 757 Engines535 = RR RB211-535C, 535E4535C = RR RB211-535C2000 = Pratt & Whitney PW 2037, PW 2040 & PW2043 EnginesNOTE = Engine Applicability Note

TASK DESCRIPTION Description of the task to be performed.COLUMN EXPLANATION

MAY 2002
757 MAINTENANCE PLANNING DATA

D622N001-9

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

K. CERTIFICATION MAINTENANCE REQUIREMENTS TASKS

MPD

ITEM

NUMBER TASK

CMR 

INTERVAL ZONE ACCESS

APPLICABILITY

757

CERTIFICATION MAINTENANCE 

APL ENG TASK DESCRIPTI

26-010-03 OPC 3000 FH 211

313314

1511

313AL

822

300 2000 Operationally Check Cargo Fire Extinguishing Firing 

Compartment Isolation (Recirc and Cargo Heating Fa

26-010-04 OPC 7500 FH 211

313314

1511

313AL

822

300 535 Operationally Check Cargo Fire Extinguishing Firing 

Compartment Isolation (Recirc and Cargo Heating Fa

26-010-05 OPC 7500 FH 211

212

300 2000 Operationally Check the Smoke Idle Engine Mode wi

Operation and With Cowl Anti-Ice On and verify High Armed.

26-015-00 OPC 48 HRS

NOTE

212 ALL ALL Operationally Check the Automatic Fire/Overheat Log

Eng/APU/Cargo Test Switch (if not checked by crew)Interval Note: Task should not exceed 48 elapsed clo

27-029-01 FNC 6000 FH 212

324335345

119BL

197KL

198PR335DB345DB

NOTE

ALL ALL Functionally Check internal leakage of Elevator and R

(Left, Center, Right) including Monitoring System.Access Note: The following access panels require op434AL and 444AL for the RR Engines and 435 AL an

27-036-00 OPC 600 FH 211 ALL ALL Operationally Check the Stall Warning Systems and A27-063-00 OPC 2000 FH

NOTE

212 ALL ALL Operationally Check TE Flap/Slat Alternate (Electric) 

Interval Note: The MSG-3 Frequency of 1C was dev

28-41-00-5A

DELETED

FNC 4000 FH 212

531541542631641642

Perform Comparison Check of each channel of the F(FQIS) using Measuring Sticks.(Main Fuel Tanks should contain less than 10,000 LB(1): SB 757-28A7. Task is applicable to airplanes prinot incorporated SB.

NOV 2010
D622N001-9

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757 MAINTENANCE PLANNING DATA

29-004-00 FNC 6000 FH 212

324335345

197KL

198PR

NOTE

ALL ALL Functionally Check Gross Internal Leakage of Each H

Right).SB 29-0026. The CMR Classification can be terminato 12,000 HRS (task remains an MRB item) provided are satisfied:1. Incorporation of SB 757-29-26 On A/Ps Prior to Lin

and on incorporate equivalent.

2. Use of BMS 3-11 Hydraulic Fluid Only.Access Note: The following access panels require op434AL and 444AL for the RR engines and 435AL and 

29-007-00 OPC 12000 FH

NOTE

143212

119BL

732

ALL ALL Check operation of Hydraulic Power Transfer Unit (P

(Audibly check PTU for Smooth Operation. Cycle flaInterval Note: MSG-3 Frequency of 1C applies and muntil the 12000 Hour CMR Developed Frequency is re

29-013-00 OPC 6000 FH 144

198212

198MR

742

ALL ALL Operationally Check Auto and Manual RAT Deploym

and Drive System.

29-017-01 VCK 600 FH 143 732 NOTE ALL Inspect position of Hydraulic Power Transfer Unit (PT

Pressure Indicator.Airplane Note: SB 757-29-0014. Task applicable to which have not incorporated this SB.

29-018-01 VCK 600 FH 444 444AL ALL ALL Inspect Hydraulic System R EDP Pressure Filter Diffe

For Position.

29-019-01 OPC 6000 FH 212 ALL ALL Operationally Check Hydraulic Pressure on EICAS M

Driven Pumps (EDP). (This also checks that the EDP 

31-004-00 OPC 100 FH 212 ALL ALL Operationally check by performing a readout of all EI

pressing the ECS/MSG Display Select Switch (if not c

31-006-01 OPC 10800 FH 211 ALL ALL Operationally Check (including L-R switching) of the 

checked by crew).

MPD

ITEM

NUMBER TASK

CMR 

INTERVAL ZONE ACCESS

APPLICABILITY

757

CERTIFICATION MAINTENANCE 

APL ENG TASK DESCRIPTI

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52-033-00 FNC 3000 FH 211

212

NOTE ALL Functionally Check the Locking and Unlocking Latch 

Door Decompression Panel.Airplane Note: Applicable to Passenger Airplanes L/

77-008-00 OPC 400 FH 212 ALL 2000 Operationally Check Standby Engine Indicator by act

by crew).

78-024-00 OPC 5000 FH

NOTE

211

212

411

421

435AL445AL

200 2000 Operationally Check the Engine 1 and Engine 2 Thru

Interval Note: If task is performed in conjunction with 

78-024-00 OPC 5000 FH

NOTE

211

212

411

421

435AL445AL

300 2000 Operationally Check the Engine 1 and Engine 2 Thru

Interval Note: If task is performed in conjunction with 

78-025-00 OPC 1000 FH

NOTE

211

212

411

421

435AL445AL

200 2000 Operationally Check the Engine 1 and Engine 2 Thru

Interval Note: If task is performed in conjunction with 

78-025-00 OPC 1000 FH

NOTE

211

212

411

421

435AL445AL

300 2000 Operationally Check the Engine 1 and Engine 2 Thru

Interval Note: If task is performed in conjunction with 

73-110-01 OPC 4000 FH 411

421

414AR424AR

ALL 535C Operationally Check by verifying proper operation of 

Reset Solenoid.

77-110-00 OPC 400 FH 212 ALL 535 Operationally Check Standby Engine Indicator by act

by crew).

78-131-00 OPC 1200 FH 415

416425426

300 535 Operationally Check the Engine 1 and Engine 2 Thru

MPD

ITEM

NUMBER TASK

CMR 

INTERVAL ZONE ACCESS

APPLICABILITY

757

CERTIFICATION MAINTENANCE 

APL ENG TASK DESCRIPTI

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78-133-00 OPC 6000 FH 210

415416425426

415FL

415KL434AL

425FL

425KL444AL

300 535 Operationally Check the Engine 1 and Engine 2 Thru

78-134-00 OPC 1200 FH 415

416425426

300 535 Operationally Check the Engine 1 and Engine 2 Thru

78-135-01 OPC 1200 FH 415

416425426

300 535 Operationally Check the Engine 1 and Engine 2 Thru

78-136-00 OPC 6000 FH 415

416425426

300 535 Operationally Check the Engine 1 and Engine 2 Thru

MPD

ITEM

NUMBER TASK

CMR 

INTERVAL ZONE ACCESS

APPLICABILITY

757

CERTIFICATION MAINTENANCE 

APL ENG TASK DESCRIPTI

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L. JAA UNIQUE REQUIREMENTS

INTRODUCTIONThe scheduled maintenance requirements described in this subsection result from Model 757-300 airplane certification activitie

Authorities (JAA). Accordingly, these JAA Airworthiness Limitations and Certification Maintenance Requirements actions are mThe complete JAA requirements include all of the FAA requirements plus the JAA unique requirements of this subsection.STRUCTURAL SAFE LIFE LIMITSBoeing Drawing 161N0006, 757 Main Landing Gear Component Interchangeability List and 162N0006, 757 Nose Landing GeaInterchangeability List, identify the 757 landing gear and support structure safe-life (life limited) parts. Boeing Document D101NEngine Mount Safe Life Part Numbers, identifies all 757-300 Rolls Royce Engine safe-life (life limited) parts. The Drawings and distributed by Service Letters 757-SL-32-030 and 757-SL-71-019.

ITEM LIFE LIMIT

757-300 Nose Landing Gear 62,000 Landings757-300 Main Landing Gear 62,000 Landings757-300 Main Landing Gear Support Structure 62,000 Landings757-300 Rolls Royce Engine Forward Mount except P/N FW62968 50,000 Landings757-300 Rolls Royce Engine Forward Mount P/N FW62968 36,000 Landings (1)757-300 Rolls Royce Engine Aft Mount 50,000 Landings(1) Rolls Royce Service Bulletin RB.211-71-AG051 replaces thrust bearing housing P/N LK83059 with P/N FW62968, which will be 

 in the Group B Parts Mandatory Inspections section of the RB.211-535 Time Limits Manual, 05-20-02.

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